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Miller XPS 350 Owner's Manual

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XPS 350 And 450
OWNER'S MANUAL
OM-249 332F
Processes
Description
Arc Welding Power Source
CE
2013−01
MIG (GMAW) Welding
Flux Cored (FCAW)

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Summary of Contents for Miller XPS 350

  • Page 1 OM-249 332F 2013−01 Processes MIG (GMAW) Welding Flux Cored (FCAW) Description Arc Welding Power Source XPS 350 And 450 OWNER’S MANUAL www.MillerWelds.com...
  • Page 2 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.

  • Page 3: Table Of Contents

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

  • Page 4: Declaration Of Conformity

    Council Directive(s) and Standard(s). Product/Apparatus Identification: Product Stock Number XPS 350,400VAC 029015528 XPS 450,400VAC 029015529 XPS 350, BASIC 400VAC 029015531 XPS 450, BASIC 400VAC 029015532 XPS 350, 230/400VAC 029015534 XPS 450 ,230/400VAC 029015535 XPS 350, BASIC 230/400VAC...

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 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 Indicates special instructions.
  • Page 6 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.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 9: Section 2 − Definitions

    SECTION 2 − DEFINITIONS 2-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Disconnect input plug or power before working on machine. Safe5 2012−05 Do not remove or paint over (cover) the label. Safe20 2012−05 Disconnect input plug or power before working on machine.
  • Page 10 Use ventilating fan to remove fumes. Safe61 2012−06 Keep flammables away from welding. Do not weld near flammables. Safe62 2012−06 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Safe63 2012−06 Do not weld on drums or any closed containers.

  • Page 11: Miscellaneous Symbols And Definitions

    2-2. Miscellaneous Symbols And Definitions Alternating Current Direct Current Amperes Volts (AC) (DC) Protective Earth Remote (Ground) Gas Metal Arc Line Connection Three Phase Hertz Welding (GMAW) Rated Maximum Maximum Effective Conventional Load Primary Voltage 1max 1eff Supply Current Supply Current Voltage Rated Welding Rated No Load...

  • Page 12: Section 3 − Introduction

    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.

  • Page 13: Duty Cycle Chart

    3-5. Duty Cycle Chart Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.

  • Page 14: Volt-Ampere Curves

    3-6. Volt-Ampere Curves XPS 350 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 DC Amperes XPS 450 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500...

  • Page 15: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Selecting a Location Position unit so air can circulate. 500 mm 500 mm 500 mm 956142796_1-10_D 4-2. Typical MIG Connections Power source Work clamp (connect to receptacle as shown) Cylinder (chain to running gear) Cylinder valve Open valve slightly so gas flow blows dirt from valve.

  • Page 16: Installing Single Bottle And Upper Bracket Support (All Models: Optional)

    4-3. Installing Single Bottle And Upper Bracket Support (All Models: Optional) Tools Needed: M8 (13 mm) Torx T30 956142796_6-10_B / 956142796_7-10_B Bottle Support Regulator/Flowmeter Chain cylinder to the support so cylin- der cannot fall and break off valve. Bottle Support Screw Install so face is vertical.

  • Page 17: Installing Double Bottle And Upper Bracket Support (All Models: Optional)

    4-4. Installing Double Bottle And Upper Bracket Support (All Models: Optional) Tools Needed: M8 (13 mm) Torx T30 956142796_4-10_B / 956142796_5-10_B Bottle Support Screw Input Gas Hose Chain cylinder to the support so cylin- der cannot fall and break off valve. Use screws to secure bottle support to Water Cooler base.

  • Page 18: Installing Input Gas And Water Cooler Hoses (All Models: Optional)

    4-5. Installing Input Gas And Water Cooler Hoses (All Models: Optional) Hose Retaining Bracket Hoses Route hoses through track in base, and use bracket to secure hoses. Water Out Fitting (Cool) Water In Fitting (Hot) Gas Out Fitting Tools Needed: Torx T30 956142796_8-10_C OM-249 332 Page 14...

  • Page 19: Weld Output Terminals And Selecting Cable Sizes

    4-6. 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.

  • Page 20: Remote 14 Receptacle Rc1

    * Power cord supplied with 230 volt units. ** Larger power cord may be required for cable length greater than 3 meters. Consult national or local regulations. XPS 350−50/60 Hz Three Phase XPS 450−50/60 Hz Three Phase Input Voltage (V)

  • Page 21: Positioning Jumper Links (230/400 Vac 3-Phase)

    4-9. Positioning Jumper Links (230/400 VAC 3-Phase) Disconnect and lockout/tag- out input power before in- stalling or moving jumper links. Follow established pro- cedures regarding the install- ation and removal of lockout/ tagout devices. All units have jumper links pre- set to 400V.

  • Page 22: Connecting Input Power

    4-10. Connecting Input Power Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Follow es- tablished procedures regarding the installation and removal of lockout/tagout devices.

  • Page 23: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls For The XPS 350 Voltage Range Control S2 Allows selection of voltage in three coarse ranges, A, B, or C. Digital Voltmeter Power On Light PL1 PL1 is lit when power is On. High Temperature Light PL2 PL2 lights up when unit overheats and shuts down.

  • Page 24: Controls For The Xps 450

    5-2. Controls For The XPS 450 Voltage Range Control S2 Allows selection of voltage in four coarse ranges, A, B, C, or D. Digital Voltmeter Power On Light PL1 PL1 is lit when power is On. High Temperature Light PL2 PL2 lights up when unit overheats and shuts down.

  • Page 25: Section 6 − Maintenance And Troubleshooting

    SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld Repair or replace cracked gas cable. hose.
  • Page 26 Trouble Remedy No 115 volts AC output at duplex Reset supplementary protector CB2 (See Section 5). receptacle. No 24 volts AC output at Remote 14 re- Reset supplementary protector CB1 (See Section 5). ceptacle. Fan not operating; fan only runs when Check for and remove anything blocking fan movement.
  • Page 27 Notes OM-249 332 Page 23...

  • Page 28: Section 7 - Electrical Diagram

    SECTION 7 - ELECTRICAL DIAGRAM Figure 6-1. Circuit Diagram for XPS 350 Digital (230/400 VAC) OM-249 332 Page 24...
  • Page 29 956142739-G OM-249 332 Page 25...
  • Page 30 Figure 6-2. Circuit Diagram for XPS 350 Digital (400 VAC) OM-249 332 Page 26...
  • Page 31 956142740-G OM-249 332 Page 27...
  • Page 32 Figure 6-3. Circuit Diagram for XPS 450 Digital (230/400 VAC) OM-249 332 Page 28...
  • Page 33 956142741-F OM-249 332 Page 29...
  • Page 34 Figure 6-4. Circuit Diagram for XPS 450 Digital (400 VAC) OM-249 332 Page 30...
  • Page 35 956142742-F OM-249 332 Page 31...
  • Page 36 Figure 6-5. Circuit Diagram for XPS 350 Basic (230/400 VAC) OM-249 332 Page 32...
  • Page 37 956142801-B OM-249 332 Page 33...
  • Page 38 Figure 6-6. Circuit Diagram for XPS 350 Basic (400 VAC) OM-249 332 Page 34...
  • Page 39 956142802-C OM-249 332 Page 35...
  • Page 40 Figure 6-7. Circuit Diagram for XPS 450 Basic (230/400 VAC) OM-249 332 Page 36...
  • Page 41 956142803-C OM-249 332 Page 37...
  • Page 42 Figure 6-8. Circuit Diagram for XPS 450 Basic (400 VAC) OM-249 332 Page 38...
  • Page 43 956142804-D OM-249 332 Page 39...

  • Page 44: Section 8 - Parts List

    SECTION 8 - PARTS LIST Ref. 956142796_2-10_F October 2, 2006 Figure 8-1. Main Assembly for XPS 350 OM-249 332 Page 40...
  • Page 45 Dia. Part Mkgs. Description Basic Digital Figure 8-1. Main Assembly for XPS 350 ....000207233 Label, general precautionary .......
  • Page 46 Dia. Part Mkgs. Description Basic Digital Figure 8-1. Main Assembly for XPS 350 (continued) ... . . +156120005 Conveyor, Fan ......... . .
  • Page 47 Notes OM-249 332 Page 43...
  • Page 48 Ref. 956142796_2-10_F Figure 8-2. Main Assembly for XPS 450 OM-249 332 Page 44...
  • Page 49 ..Label, Miller logo ........
  • Page 50 Quantity Model Item Dia. Part Mkgs. Description Basic Digital Figure 8-2. Main Assembly for XPS 450 (continued) ... 057079039 ..Contactor, CN−65 24V (230/400 VAC) ..... .
  • Page 51 Effective January 1, 2013 (Equipment with a serial number preface of MD 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 90 Days —...
  • Page 52 File a claim for loss or damage during Phone: 39 (0) 2982901 Fax: 39 (0) 298290-203 shipment. 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 2013 Miller Electric Mfg. Co. 2013−01...

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