Miller XMS 425 MPa CE User manual

Arc Welding Power Source
XMS 425 MPa
CE
OM-274462C 2017-02
Processes
Description
MultiprocessWelding
File: MULTIPROCESS
For product information, Own-
er’s Manual translations, and
more, visit
www.MillerWelds.com

Thank you and congratulations on choosing Miller. Now you can get the
job done and get it done right. We know you don’t have time to do it any
other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior quality.
Like you, his customers couldn’t afford anything less. Miller products had
to be more than the best they could be. They had to be the best you could
buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.
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.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You

TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................
1-1. Symbol Usage 1.......................................................................
1-2. Arc Welding Hazards 1.................................................................
1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................
1-4. California Proposition 65 Warnings 4......................................................
1-5. Principal Safety Standards 4.............................................................
1-6. EMF Information 4.....................................................................
SECTION 2 − DEFINITIONS 5..................................................................
2-1. Additional Safety Symbols And Definitions 5................................................
2-2. Miscellaneous Symbols And Definitions 7..................................................
SECTION 3 − SPECIFICATIONS 8..............................................................
3-1. Serial Number And Rating Label Location 8................................................
3-2. Unit Specifications 8....................................................................
3-3. Dimensions And Weight 8...............................................................
3-4. Environmental Specifications 9...........................................................
3-5. Duty Cycle And Overheating 10...........................................................
3-6. Volt-Ampere Curves 11..................................................................
SECTION 4 − INSTALLATION 12................................................................
4-1. Selecting A Location 12..................................................................
4-2. Selecting Cable Sizes 13.................................................................
4-3. Weld Output Terminals 13................................................................
4-4. Remote 14 Receptacle Information 14......................................................
4-5. 115 Volts AC Duplex Receptacle And Supplementary Protectors 14.............................
4-6. Optional Gas Valve Operation And Shielding Gas Connection 15...............................
4-7. Cooler Connections 16...................................................................
4-8. 7-Pin Receptacle Information 16...........................................................
4-9. Wire Feeder Connections 17..............................................................
4-10. 6-Pin Receptacle Information 17...........................................................
4-11. TIG Connections 18.....................................................................
4-12. Stick Connections 19....................................................................
4-13. MIG Connections 20.....................................................................
4-14. Electrical Service Guide 21...............................................................
4-15. Connecting 3-Phase Input Power 22.......................................................
SECTION 5 − OPERATION 24...................................................................
5-1. Front Panel Controls 24..................................................................
5-2. Lift-Arc Trigger Hold TIG 25...............................................................
5-3. Stick Start Procedure 25.................................................................
SECTION 6 − MAINTENANCE & TROUBLESHOOTING 26.........................................
6-1. Routine Maintenance 26.................................................................
6-2. Blowing Out Inside Of Unit 26.............................................................
6-3. Troubleshooting 27......................................................................
SECTION 7 − ELECTRICAL DIAGRAM 28........................................................
SECTION 8 − PARTS LIST 30...................................................................
WARRANTY

DECLARATION OF CONFORMITY
for European Community (CE marked) products.
ITW Welding Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that the prod-
uct(s) identified in this declaration conform to the essential requirements and provisions of the stat-
ed Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product Stock Number
XMS 425 MPa, CE 029015507
Council Directives:
•2014/35/EU Low Voltage
•2014/30/EU Electromagnetic Compatibility
•2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
•IEC 60974-1:2012 Arc Welding Equipment - Part 1: Welding Power Sources
•IEC 60974-10:2014+A1:2015 Arc Welding Equipment - Part 10: Electromagnetic Compatibility Requirements
EU Signatory:
November 8th, 2016
___________________________________________________________________________________
Massimigliano Lavarini Date of Declaration
ITW WELDING ITALY PRODUCTION MANAGER
956 172 249

EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product Stock Number
XMS 425 MPa 029015507
Compliance Information Summary
Applicable regulation Directive 2014/35/EU
Reference limits Directive 2013/35/EU, Recommendation 1999/51 9/EC
Applicable standards IEC 62822−1:2016, IEC 62822−2:2016
Intended use ☒for occupational use ☐for use by laymen
Non−thermal effects need to be considered for workplace assessment ☒YES ☐NO
Thermal effects need to be considered for workplace assessment ☐YES ☒NO
☒Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs) ☒YES ☐NO
for health effects at the standardized configurations (if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs) ☐n.a ☒YES ☐NO
for sensory effects at the standardized configurations (if applicable and NO, specific measures are needed)
Occupational exposure is below the Action Levels (ALs) at the ☐n.a ☐YES ☒NO
standardized configurations (if applicable and NO, specific signage is needed)
EMF Data for Non-thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Trunk Limb (hand)
Limb (thigh)
Sensory
Effects Health
Effects
Standardized distance 10 cm 10 cm 10 cm 3 cm 3 cm
ELV EI @ standardized distance 0.16 0.12 0.19 0.11 0.24
Required minimum distance 1 cm 1 cm 1 cm 1 cm 1 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%) 9 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%) 185 cm
Tested by: Miller Milan Date tested: 2016−03−03
XXXXXX‐A

OM-274462 Page 1
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plainedin the text.
NOTICE − Indicates statements not related to personal injury.
.Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is on-
ly a summary of the more complete safety information found
in the Safety Standards listed in Section 1-5. Read and follow
all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
Touchinglive electrical parts can cause fatal shock
s
or severe burns. The electrode and work circuit i
s
electricallylive whenever the output is on. The inpu
t
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automati
c
wire welding, the wire, wire reel, drive roll housing
,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperl
y
groundedequipment is a hazard.
DDo not touch live electrical parts.
ELECTRIC SHOCK can kill.
DWear dry, hole-free insulating gloves and body protection.
DInsulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
DDo not use AC output in damp areas, if movement is confined, or if
thereis a danger of falling.
DUse AC output ONLY if required for the welding process.
DIf AC output is required, use remote output control if present on
unit.
DAdditionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locationsor while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
ableor accidental contact with the workpiece or ground. For these
conditions,use the following equipment in order presented: 1) a
semiautomaticDC 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
is recommended. And, do not work alone!
DDisconnectinput power or stop engine before installing or servic-
ing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
DProperly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
DAlways verify the supply ground − check and be sure that input
powercord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly ground-
ed receptacle outlet.
DWhenmaking input connections, attach proper grounding conduc-
tor first − double-check connections.
DKeepcords dry, free of oil and grease, and protected from hot metal
and sparks.
DFrequently inspect input power cord and ground conductor for
damageor bare wiring – replace immediately if damaged – bare
wiring can kill.
DTurn off all equipment when not in use.
DDo not use worn, damaged, undersized, or repaired cables.
DDo not drape cables over your body.
DIf earth grounding of the workpiece is required, ground it directly
with a separate cable.
DDo not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
DDo not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
DUse only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
DWear a safety harness if working above floor level.
DKeep all panels and covers securely in place.
DClamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
DInsulate work clamp when not connected to workpiece to prevent
contact with any metal object.
DDo not connect more than one electrode or work cable to any sin-
gle weld output terminal. Disconnect cable for process not in use.
DUse GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing power sources AFTER removal of input power.
DTurn Off inverter, disconnect input power, and discharge input ca-
pacitors according to instructions in Maintenance Section before
touching any parts.
HOT PARTS can burn.
DDo not touch hot parts bare handed.
DAllow cooling period before working on equip-
ment.
DTo handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.

OM- 274462 Page 2
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
DKeep your head out of the fumes. Do not breathe the fumes.
DIf inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
DIf ventilation is poor, wear an approved air-supplied respirator.
DRead and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables,coolants, degreasers, fluxes, and metals.
DWork in a confined space only if it is well ventilated, or while wear-
ing an air-supplied respirator. Always have a trained watchperson
nearby. Welding fumes and gases can displace air and lower the
oxygen level causing injury or death. Be sure the breathing air is
safe.
DDo not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
DDo not weld on coated metals, such as galvanized, lead, or cadmi-
um plated steel, unless the coating is removed from the weld area,
the area is well ventilated, and while wearing an air-supplied respi-
rator. The coatings and any metals containing these elements can
give off toxic fumes if welded.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
DWear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
DWear approved safety glasses with side shields under your hel-
met.
DUse protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
DWear body protection made from durable, flame−resistant mate-
rial (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
ARC RAYS can burn eyes and skin.
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
workpiece,and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
WELDING can cause fire or explosion.
DRemove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
DDo not weld where flying sparks can strike flammable material.
DProtect yourself and others from flying sparks and hot metal.
DBe alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
DWatch for fire, and keep a fire extinguisher nearby.
DBe aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
DDo not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
DDo not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
DConnect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknownpaths and causing electric shock, sparks, and fire haz-
ards.
DDo not use welder to thaw frozen pipes.
DRemovestick electrode from holder or cut off welding wire at con-
tact tip when not in use.
DWear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothingsuch as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
DRemove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
DAftercompletion of work, inspect area to ensure it is free of sparks,
glowingembers, and flames.
DUse only correct fuses or circuit breakers. Do not oversize or by-
pass them.
DFollowrequirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
DRead and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables,coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
DWelding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
DWear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
DShutoff compressed gas supply when not in use.
DAlways ventilate confined spaces or use ap-
proved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EM
F)
can affect Implanted Medical Devices.
DWearers of Pacemakers and other Implante
d
MedicalDevices should keep away.
DImplantedMedical Device wearers should consult their docto
r
and the device manufacturer before going near arc welding, spo
t
welding,gouging, plasma arc cutting, or induction heating
operations.
Noise from some processes or equipment can
damagehearing.
DWear approved ear protection if noise lev-
el is high.
NOISE can damage hearing.
Compressedgas cylinders contain gas under high
pressure.If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
CYLINDERS can explode if damaged.
DProtect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
DInstall cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
DKeepcylinders away from any welding or other electrical circuits.
DNever drape a welding torch over a gas cylinder.
DNever allow a welding electrode to touch any cylinder.
DNever weld on a pressurized cylinder − explosion will result.
DUse only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
DTurn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
DKeepprotective cap in place over valve except when cylinder is in
use or connected for use.
DUse the right equipment, correct procedures, and sufficientnum-
ber of persons to lift and move cylinders.
DRead and follow instructions on compressed gas cylinders, asso-
ciated equipment, and Compressed Gas Association (CGA)
publicationP-1 listed in Safety Standards.

OM-274462 Page 3
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
DDo not install or place unit on, over, or near
combustiblesurfaces.
DDo not install unit near flammables.
DDo not overload building wiring − be sure power supply system is
properlysized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
DUse lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
DUse equipment of adequate capacity to lift and
supportunit.
DIf using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
DKeepequipment (cables and cords) away from moving vehicles
when working from an aerial location.
DFollowthe guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
DAllow cooling period; follow rated duty cycle.
DReduce current or reduce duty cycle before
startingto weld again.
DDo not block or filter airflow to unit.
FLYING SPARKS can injure.
DWear a face shield to protect eyes and face.
DShape tungsten electrode only on grinder with
properguards in a safe location wearing proper
face, hand, and body protection.
DSparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
DPut on grounded wrist strap BEFORE handling
boards or parts.
DUse proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can injure.
DKeep away from moving parts.
DKeep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
DDo not press gun trigger until instructed to do
so.
DDo not point gun toward any part of the body,
other people, or any metal when threading
weldingwire.
BATTERY EXPLOSION can injure.
DDo not use welder to charge batteries or jum
p
start vehicles unless it has a battery chargin
g
feature designed for this purpose.
MOVING PARTS can injure.
DKeep away from moving parts such as fans.
DKeep all doors, panels, covers, and guards
closed and securely in place.
DHave only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
DReinstalldoors, panels, covers, or guards when maintenance is
finishedand before reconnecting input power.
READ INSTRUCTIONS.
DRead and follow all labels and the Owner’s
Manualcarefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each sec-
tion.
DUse only genuine replacement parts from the manufacturer.
DPerforminstallation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
H.F. RADIATION can cause interference.
DHigh-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
DHave only qualified persons familiar with elec-
tronic equipment perform this installation.
DThe user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
DIf notified by the FCC about interference, stop using the equip-
ment at once.
DHave the installation regularly checked and maintained.
DKeephigh-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimizethe possibility of interference.
ARC WELDING can cause interference.
DElectromagneticenergy can interfere with sen-
sitive electronic equipment such as computers
and computer-driven equipment such as ro-
bots.
DBe sure all equipment in the welding area is
electromagneticallycompatible.
DTo reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
DLocate welding operation 100 meters from any sensitive elec-
tronic equipment.
DBe sure this welding machine is installed and grounded accord-
ing to this manual.
DIf interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables, us-
ing line filters, or shielding the work area.

OM- 274462 Page 4
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductiveharm. Wash hands after use.
1-5. Principal Safety Standards
SafetyinWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.orgor purchased from Global Engineering Documents
(phone:[phone], website: www.global.ihs.com).
SafePractices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: [phone], website:
www.global.ihs.com).
SafePractices for Weldingand Cutting Containers that have Held Com-
bustibles,American Welding Society Standard AWS A6.0, from Global
EngineeringDocuments (phone: [phone],
website: www.global.ihs.com).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.organd www. sparky.org).
SafeHandling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga-
net.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2,from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone:[phone], website: www.csagroup.org).
SafePractice For Occupational And Educational Eye And Face Protec-
tion,ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: [phone], web-
site: www.ansi.org).
Standardfor Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Of-
fices—phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
ApplicationsManual for the Revised NIOSH Lifting Equation, The Na-
tional Institute for Occupational Safety and Health (NIOSH), 1600
CliftonRd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and
inductionheating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace-
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding,gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.

OM-274462 Page 5
SECTION 2 − DEFINITIONS
2-1. Additional Safety Symbols And Definitions
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
Disconnectinput plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keepflammables away from welding. Do not weld near flammables.
Safe12 2012−05
Weldingsparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not remove or paint over (cover) the label.
Safe20 2012−05

OM-274462 Page 6
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
After taking proper precautions as shown, connect power to unit.
Safe29 2012−05
Do not use one handle to lift or support unit.
Safe31 2012−05
Do not weld on drums or any closed containers.
Safe16 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information. Safe37 2012−05
Disconnectinput plug or power before working on machine.
Safe30 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Becometrained and read the instructions before working on the
machine or welding.
Safe40 2012−05
=<60°Always lift and support unit using both handles. Keep angle of lifting
device less than 60 degrees.
Use a proper cart to move unit.
Safe44 2012−05
>60s
V
V
V
Hazardous voltage remains on input capacitors after power is turned
off. Do not touch fully charged capacitors. Always wait 60 seconds
after power is turned off before working on unit, OR check input ca-
pacitor voltage, and be sure it is near 0 before touching any parts.
Safe42 2012−05

OM-274462 Page 7
2-2. Miscellaneous Symbols And Definitions
AAmperage
Alternating
Current(AC)
VVoltage
On
Voltage Input
Protective Earth
(Ground)
Line Connection
Three Phase Stat-
ic Frequency Con-
verter-Trans-
former-Rectifier
XDuty Cycle
%
Percent
Three Phase
Gas Metal Arc
Welding (GMAW)
Remote
Negative
Temperature
MMA Welding
Tungsten Inert
Gas (TIG)
Welding
U2Conventional
Load Voltage
I
2Rated Welding
Current
Single Phase
Circuit Breaker
Positive
Constant Voltage
U
1Primary Voltage
IP
Degree Of Protec-
tion
I
1eff Maximum
Effective Supply
Current
Output
Off
Direct Current
(DC)
I
1max Rated Maximum
Supply Current

OM-274462 Page 8
SECTION 3 − SPECIFICATIONS
3-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on back cover of this manual.
3-2. Unit Specifications
.Do not use information in unit specifications table to determine electrical service requirements. See Sections 4-14 and 4-15 for information on
connecting input power.
.This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C).
Input
Power Rated Output Voltage Range in
CV Mode
Amperage
Range in
CC Mode
Max.
Open-
Circuit
Voltage
RMS Amps Input at Rated Load Output,
50/60 Hz 3-Phase at NEMA Load Voltages and
Class I Rating
KVA KW
230 V 380 V 400 V 460 V
3-Phase 350 A at 34
VDC, 60%
Duty Cycle
10−38 V 5−425 A 75 VDC 36.1 22.3 20.6 17.8 14.2 13.6
*See Section 3-5 for Duty Cycle Rating.
3-3. Dimensions And Weight
.Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.
A. Welding Power Source
Dimensions
956172246_3-A
A597 mm (23.5 in.)
B349 mm (13−3/4 in.)
C560 mm (22 in.)
D521 mm (20.5 in.)
E25.3 mm (1 in.)
F298.5 mm (11−3/4 in.)
G12.7 mm (0.5 in.)
Weight
52.5 kg (115.7 lb)
B. Welding Power Source With Cart And Cooler
Dimensions
956172246_4-A
A1510mm (59.5 in.)
B810 mm (31.9 in.)
C1110 mm (43.7 in.)
Weight
130 kg (287 lb)

OM-274462 Page 9
3-4. Environmental Specifications
A. IP Rating
IP Rating
IP23S
This equipment is designed for outdoor use. It may be stored,
but is not intended to be used for welding outside during precipitation unless sheltered. IP23S 2014−06
B. Temperature Specifications
OperatingTemperature Range Storage Temperature Range
14 to 104°F (−10 to 40°C) −4 to 131°F (−20 to 55°C) Temp_2016-07
C. Information On Electromagnetic Compatibility (EMC)
!This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−volt-
age supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con-
ducted as well as radiated disturbances.
This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Zmax at the point of common coupling is less than 183 mW(or the short−circuit power Ssc is greater than
873,042.200VA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator
if necessary, that the system impedance complies with the impedance restrictions. ce-emc 1 2014-07
Notes

OM-274462 Page 10
6 Minutes Welding 4 Minutes Resting
3-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
withoutoverheating.
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
Overheating 0
15
A or V
OR
Reduce Duty Cycle
Minutes
Ref. 219 523-A
Notes

OM-274462 Page 11
3-6. Volt-Ampere Curves
217 836-A / 217 837-B
Volt-ampere curves show minimum
and maximum voltage and amper-
age output capabilities of welding
power source. Curves of other set-
tings fall between curves shown.
0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400 500
50% 75%
100%
25%
0%
AMPERAGE
VOLTS
A. CC Mode
GTAW
MAX
SMAW
MAX
SMAW
80A ARC
CONTROL
GTAW
MN
0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400 500
VOLTS
B. CV Mode
AMPERAGE
MAX
MIN
Notes

OM-274462 Page 12
SECTION 4 − INSTALLATION
!Special installation may be
required where gasoline or
volatileliquids are present −
see NEC Article 511 or CEC
Section20.
1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to
move unit.
If using lifting forks, extend forks
beyondopposite side of unit.
3 Line Disconnect Device
Locate unit near correct input
power supply.
4-1. Selecting A Location
3
18 in.
(460 mm)
18 in.
(460 mm)
OR
1
2
Movement
Location And Airflow
loc_large 2015-04
!Do not move or operate unit
where it could tip.
Notes

OM-274462 Page 13
4-2. 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 30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine
cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
30 m (100 ft) or Less 45 m (150
ft) 60 m (200 ft) 70 m (250 ft) 90 m (300 ft) 105 m (350 ft) 120 m (400 ft)
Welding
Amperes
10 − 60%
Duty Cy-
cle
mm2(AWG)
60 − 100%
Duty Cycle
mm2(AWG)
10 − 100% Duty Cycle
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)
250 35 (2) 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2x2/0) 2x70 (2x2/0)
300 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2x2/0) 2x95 (2x3/0) 2x95 (2x3/0)
350 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2x2/0) 2x95 (2x3/0) 2x95 (2x3/0) 2x120 (2x4/0)
400 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2x2/0) 2x95 (2x3/0) 2x120 (2x4/0) 2x120 (2x4/0)
500 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2x2/0) 2x95 (2x3/0) 2x120 (2x4/0) 3x95 (3x3/0) 3x95 (3x3/0)
600 95 (3/0) 120 (4/0) 2x70 (2x2/0) 2x95 (2x3/0) 2x120 (2x4/0) 3x95 (3x3/0) 3x120 (3x4/0) 3x120 (3x4/0)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
***For distances longer than those shown in this guide, call a factory applications representative. Milan Ref. S-0007-L 2015−02
4-3. Weld Output Terminals
!Turn off power before connecting
to weld output terminals.
!Do not use worn, damaged, un-
dersized, or repaired cables.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
1
2
Ref. 956172246_14-A

OM-274462 Page 14
4-4. Remote 14 Receptacle Information
AJ
BKI
CLNH
DMG
EF
Socket* Socket Information
24 VOLTS AC A24 volts AC. Protected by supplementary protect-
or CB2.
BContact closure to A completes 24 volts AC con-
tactor control circuit.
REMOTE
OUTPUT
CONTROL
COutput to remote control; 0 to +10 volts DC, +10
volts DC in MIG mode.
DRemote control circuit common.
E0 to +10 volts DC input command signal from re-
mote control.
A/V
AMPERAGE
VOLTAGE
FCurrent feedback; +1 volt DC per 100 weld am-
peres.
HVoltage feedback; +1 volt DC per 10 weld volts.
GND GCircuit common for 24 and 115 volts AC circuits.
KChassis common.
*The remaining sockets are not used.
1 115 V AC Duplex Receptacle
10 Amp.
2 Supplementary Protector CB1
3 Supplementary Protector CB2
CB1 protects the duplex receptacle
from overload.
CB2 protects 24 volts AC portion of
Remote 14 receptacle and XMS
MPa cooler from overload.
Press button to reset protector.
1
4-5. 115 Volts AC Duplex Receptacle And Supplementary Protectors
956172246_5-A
23