Miller XMS 403 Owner'S Manual Download

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Processes

Multiprocess Welding

OM-244 243B

2009

−

Description

Arc Welding Power Source

XMS 403

(400 Volts) CE

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www.MillerWelds.com

Summary of Contents for XMS 403

Page 1: ...Processes Multiprocess Welding OM 244 243B 2009 10 Description Arc Welding Power Source XMS 403 400 Volts CE R Visit our website at www MillerWelds com...

Page 2: ...ucts 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...

Page 3: ...14 3 13 Electrical Service Guide 14 3 14 Connecting 3 Phase Input Power 15 SECTION 4 OPERATION 16 4 1 Front Panel Controls 16 4 2 Switching On the Unit and Recalling Factory Parameters 17 4 3 Welding...

Page 4: ...Directive Standards IEC 60974 1 Arc Welding Equipment Welding Power Sources edition 3 0 2005 07 IEC 60974 2 Arc Welding Equipment Water cooling systems edition 2 0 2007 11 IEC 60974 10 Arc Welding Eq...

Page 5: ...lds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following e...

Page 6: ...less they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to t...

Page 7: ...panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels cover...

Page 8: ...ther Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try...

Page 9: ...rks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use...

Page 10: ...s of parts can cause injury Always wear a face shield when servicing unit 8 Always wear long sleeves and button your collar when servicing unit 9 After taking proper precautions as shown connect power...

Page 11: ...ean filter and check condition of hoses 6 Read Owner s Manual 7 Use coolant suggested by manufacturer B 050024004 1 Warning Watch Out There are possible hazards as shown by the symbols 2 Falling unit...

Page 12: ...dispose of used coolant in an environmentally safe way U1 Primary Voltage I1max Rated Maximum Supply Current I1eff Maximum Effective Supply Current Wire Feed Speed U2 Conventional Load Voltage I2 Rat...

Page 13: ...he EMF exposure values were less than 20 of the permissible values 3 2 Serial Number And Rating Label Location The serial number and rating information for this product is located on the back panel Us...

Page 14: ...urntable for Wire Feeder on Power Source Optional Turn off welding power source and disconnect in put power before proceed ing Remove wire spool 1 Turntable 2 Screw Remove the 4 screws and the plas ti...

Page 15: ...le Do not use handle to lift unit 2 Line Disconnect Device Locate unit near correct input power supply Special installation may be required where gasoline or volatile liquids are present see NEC Artic...

Page 16: ...ick Gas 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 1...

Page 17: ...plied remote control is required to use the remote receptacle Some signals can be enabled when TIG or Stick welding Contact Factory Authorized Service Agent for confirmation 3 11 Circuit Breakers Circ...

Page 18: ...those listed in the table voids the warranty on any parts that come in contact with the coolant pump radiator etc 1 2 Ref 956142645 4 5 3 13 Electrical Service Guide Elec Serv 2009 08 Actual input vol...

Page 19: ...onductors L1 L2 and L3 to disconnect device line terminals 7 Over Current Protection Select type and size of over current protection using Section 3 13 fused dis connect switch shown Close and secure...

Page 20: ...se lected welding process During welding it shows measured welding current 12 E1 Encoder Control 1 Use control to change values and parame ters that appear on display D1 13 E2 Encoder Control 2 Use co...

Page 21: ...ing this procedure 1 Power Switch Use power switch to turn unit On When XMS 403 appears on D1 and D2 press P3 and P8 simultaneously When MEMO CLEAR appears on D1 and D2 release P3 and P7 Wait until DO...

Page 22: ...ting knob P1 scrolls through the following options W UN AUTO Rotate P2 to select water cooling unit mode AUTO Default ON Continuous or OFF Water cooling not required RCTY 1 Selects function mode for r...

Page 23: ...fer If L2 is flashing this indicates that the welding parameters are outside of the specific setting required for either arc transfer to exist This process is known as Globular Arc transfer This proc...

Page 24: ...lecting AlMg AlMg5 or AlSi AlSi5 Special permits selection of cored wire or special wire types Abbreviations for the different wire types appear in displays D1 and D2 Wire type selection is retained i...

Page 25: ...plays set current Press P7 to select the desired trigger mode L14 ON selects 2T trigger mode When trigger is pressed welding starts When trigger is released welding stops L15 ON selects 4T trigger mod...

Page 26: ...ollows Follow safety precautions according to Section 1 Prepare unit according to Section 3 Use the correct interconnecting cable to connect power source unit to the wire feed er see Wire Feeder manua...

Page 27: ...speed and arc voltage will appear on D1 and D2 During Setting D1 value is default voltage setting of 18 5 V range is 10 0 V to 50 0 V D2 value is default wire feed speed setting of 5 0 m min range is...

Page 28: ...wire diameter and gas type selection D2 value is the default current setting range is defined by wire type wire diame ter and gas type selection During Synergic MIG Welding D1 value is Measured Weldi...

Page 29: ...push button See wire feeder manual for all the remaining Synergic MIG settings Setting Cooler Status see Section 4 3 Setting Synergic Double Pulsed MIG Welding Some metals weld better using the Syner...

Page 30: ...urrent Use E1 to change D1 to IN A Initial Cur rent D2 value is default setting of 20 A range is 5 A to 400 A Use E2 to change D2 value This parameter allows starting the welding process at a lower in...

Page 31: ...Positive power connector 2 Connect work clamp cable to the negative connector 3 If a remote control is desired connect it to the Remote Control receptacle 4 Turn unit On Allow time for unit to comple...

Page 32: ...conditions 3 Months Replace Damaged Or Unreadable Labels Replace Cracked Torch Body Repair Or Replace Cracked Cables Repair Or Replace Cracked Cables And Cords Clean And Tighten Weld Connections 6 Mo...

Page 33: ...Factory Authorized Service Agent Help 9 Indicates a shorted thermistor RT1 on right side of unit Contact a Factory Authorized Service Agent Help 15 Indicates a malfunctioning cooling unit Unit will s...

Page 34: ...OM 244 243 Page 30 SECTION 6 ELECTRICAL DIAGRAM Figure 6 1 Circuit Diagram For XMS 403...

Page 35: ...OM 244 243 Page 31 956142623...

Page 36: ...OM 244 243 Page 32 SECTION 7 PARTS LIST Hardware is common and not available unless listed 956142645A 1 5 12 17 18 16 15 14 13 12 11 10 9 8 7 6 23 5 19 20 21 22 1 2 4 3 Figure 7 1 Unit Outer Assembly...

Page 37: ...22287 Side Panel R 1 14 V56142305 Nameplate Front Dinse Negativ 1 15 056054074 Wheel Caster Front 2 16 V56142303 Nameplate Front Dinse Positiv 1 17 000207291 Label Primary Power Connections 1 18 V1612...

Page 38: ...ss listed 956142645A 2 5 18 37 36 33 47 48 45 46 61 52 53 55 54 60 59 57 56 8 7 17 11 19 21 32 35 34 20 32 31 30 29 28 27 26 22 25 24 23 12 13 42 41 40 39 38 43 49 51 44 34 62 49 33 32 63 64 65 66 58...

Page 39: ...14 Pin 1 28 656026097 Hose 5x8 5x940 Black Gas 1 29 656026099 Hose 6x11x470 Blu Water 1 30 656026102 Hose 6x11x270 Red Water 1 31 000188192 Receptacle Gas 1 32 000208967 Receptacle Dinse 3 33 5560494...

Page 40: ...ut 1 66 V57014066 Primary Cable 4 Core 6 0 Mq 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of y...

Page 41: ...Notes 229895 MATERIAL THICKNESS GAUGE...

Page 42: ...mm 10 mm 5 16 in 3125 in 1 2 in 9 16 in 8 mm 3150 in 14 mm 14 mm 3 8 in 375 in 9 16 in 5 8 in 10 mm 3937 in 17 mm 17 mm 7 16 in 4375 in 5 8 in 3 4 in 12 mm 4724 in 19 mm 19 mm 1 2 in 500 in 3 4 in 13...

Page 43: ...06 5 6 Months Batteries 6 90 Days Parts MIG Guns Induction Heating Coils and Blankets Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Lim...

Page 44: ...ountry Zip Postal Code Please complete and retain with your personal records Owner s Record Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding S...

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