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Miller Electric XMT 304 CC/CV manual

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Table of contents for the manual

  • Page 1

    Processes Multiprocess W elding OM-233 045C 2007 − 10 Description Arc W elding Power Source XMT 304 CC/CV (400 V olt Models) (RoHS) R V isit our website at www.MillerWelds.com File: MUL TIPROCESS[...]

  • Page 2

    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 specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    dec_con1_1/07 Declaration of Conformity For European Community (CE) Products . This information is provided for units with CE certification (see rating label on unit). Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W . Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r .l. Phone: [...]

  • Page 5

    OM-233 045 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007 − 04 7 Protect yourself and others from injury — read and follow these precautions. 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[...]

  • Page 6

    OM-233 045 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poo[...]

  • Page 7

    OM-233 045 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.[...]

  • Page 8

    OM-233 045 Page 4 1-4. California Proposition 65 W arnings W elding 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.) Battery posts, terminals and related accessories contain lead and [...]

  • Page 9

    OM-233 045 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007 − 04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es u t ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures gra[...]

  • Page 10

    OM-233 045 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CH[...]

  • Page 11

    OM-233 045 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants m[...]

  • Page 12

    OM-233 045 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de toucher d[...]

  • Page 13

    OM-233 045 Page 9 2-5. P r i nc ip al e s no r m e s de sé c ur i té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , Amer[...]

  • Page 14

    OM-233 045 Page 10[...]

  • Page 15

    OM-233 045 Page 1 1 SECTION 3 − DEFINITIONS 3-1. Manufacturer ’ s W arning Label Definitions W arning! W atch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 1.1 W ear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect [...]

  • Page 16

    OM-233 045 Page 12 > 60 s V S-179 190-A V V 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on machine. 4 Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. 5 Always wait 6[...]

  • Page 17

    OM-233 045 Page 13 3-2. Manufacturer ’ s Rating Label Ref. 235 855-A 3-3. WEEE Label Do not discard this product with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collec- tion facility . Contact your local recycling of fice or your local distributor for further information.[...]

  • Page 18

    OM-233 045 Page 14 3-4. Symbols And Definitions A Amperage Panel Alternating Current (AC) V V oltage Output Circuit Breaker Remote On Of f Gas Tungsten Arc W elding Negative V oltage Input Direct Current (DC) Positive Inductance Protective Earth (Ground) Constant Current Constant V oltage Foot Control Line Connection Arc Force Shielded Metal Arc W [...]

  • Page 19

    OM-233 045 Page 15 SECTION 4 − INST ALLA TION 4-1. Specifications Rated W elding Output V oltage Range Amperage Range Maximum Open-Circuit V oltage DC IP Rating Amperes Input at Rated Load Output 50/60 Hz Output Range Range V o l tage DC 400 V KV A KW 300 A @ 32 V olts DC, 60% Duty Cycle 10 − 35 5 − 400 90 23 17.0 (0.15*) 12.4 (0.09*) 1 1.5 ([...]

  • Page 20

    OM-233 045 Page 16 4-3. V olt-Ampere Curves va_curve1 4/95 − SA-178 652 / SA-178 653 V olt-ampere curves show minimum and maximum voltage and amper- age output capabilities of unit. Curves of other settings fall be- tween curves shown. A. CC Mode B. CV Mode ARC CONTROL[...]

  • Page 21

    OM-233 045 Page 17 4-4. Selecting A Location loc_2 3/96 - ST -801 192 1 Lifting Handles Use handles to lift unit. 2 Hand Cart Use cart or similar device to move unit. 3 Plate Label Use label to determine input power needs. 4 Line Disconnect Device Locate unit near correct input power supply . ! Special installation may be required where gasoline or[...]

  • Page 22

    OM-233 045 Page 18 4-5. W eld Output T erminals And Selecting Cable Sizes ! ARC WELDING can cause Electromagnetic Interference. T o reduce possible interference, keep weld cables as short as possible, close together , and down low , such as on the floor . Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this weld[...]

  • Page 23

    OM-233 045 Page 19 4-6. Remote 14 Receptacle Information Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by circuit breaker CB2. AJ B K I 24 VOL TS AC B Contact closure to A completes 24 volts ac con- tactor control circuit. B I C L NH 1 15 VOL TS AC I 1 15 volts ac. Protected by circuit breaker CB1. C D M G E F 1 15 VOL TS AC J Co[...]

  • Page 24

    OM-233 045 Page 20 4-8. Electrical Service Guide NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of input power at rated frequency (+ 10%) and voltage (+ 10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera- tor with automatic id[...]

  • Page 25

    OM-233 045 Page 21 4-9. Connecting 3-Phase Input Power 2/04 - Ref. 802 136-A / 801 192 ! Installation must meet all National an d Local Codes − have only quali- fied persons make this installation. ! Disconnect and lockout/tagout in- put power before connecting input conductors from unit. ! Always connect green or green/ yellow conductor to suppl[...]

  • Page 26

    OM-233 045 Page 22 SECTION 5 − OPERA TION 5-1. Front Panel Controls 1 Power On/Of f Switch . The fan motor is thermostatically controlled and only runs when cooling is needed. 2 V oltmeter (see Section 5-2) 3 Ammeter (see Section 5-2) 4 V oltage/Amperage Adjustment Control 5 Mode Switch Th e Mode switch setting determines both the process and out[...]

  • Page 27

    OM-233 045 Page 23 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 Scratch Start TIG (GT AW) Actual V olts (OCV) Preset Amps VA 80.0 85 Lift-Arc T rigger Hold TIG (GT AW) VA Blank Preset Amps 85 TIG (GT AW) Blank Preset Amps VA 85 MIG (GMAW) [...]

  • Page 28

    OM-233 045 Page 24 5-3. Mode Switch Settings . Th e SMA W 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 Output Control Scratch Start TIG (GT AW) Select: or Amp W eld Lift-Arc T rigger Hold T[...]

  • Page 29

    OM-233 045 Page 25 5-4. Lift-Arc T rigger Hold TIG 1 TIG Electrode 2 W orkpiece . Procedure requires: Start sequence: • T ouch tungsten electrode to workpiece at weld start point. • Momentarily depress output switch. • Slowly lift electrode. An arc will form when electrode is lifted. • T o stop welding, momentarily depress output switch and[...]

  • Page 30

    OM-233 045 Page 26 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance . Maintain more often during severe conditions. ! Disconnect power before maintaining. 3 Months Replace Damaged Or Unreadable Labels Replace Cracked T orch Body Repair Or Replace Cracked Cables Repair Or Replace Cracked Cables And Cords Clean And Tighten W e[...]

  • Page 31

    OM-233 045 Page 27 6-3. V oltmeter/Ammeter Help Displays . Al l directions are in reference to the front of the unit. All circuitry referred to is lo- cated inside the unit. 1 Help 0 Display Indicates a shorted thermistor R T2 on the left side of the unit. If this display is shown, con- tact a Factory Authorized Service Agent. 2 Help 1 Display Indi[...]

  • Page 32

    OM-233 045 Page 28 6-4. T roubleshooting T rouble Remedy No weld output; unit completely inop- erative Place line disconnect switch in On position (see Section 4-9). era ti ve. Check and replace line fuse(s), if necessary , or reset circuit breaker (see Section 4 -9). Check for proper input power connections (see Section 4-9). No weld output; meter[...]

  • Page 33

    OM-233 045 Page 29 SECTION 7 − ELECTRICAL DIAGRAM 197 552 Figure 7-1. Circuit Diagram For Welding Power Source[...]

  • Page 34

    OM-233 045 Page 30 SECTION 8 − P ARTS LIST 801 605-H Figure 8.1. Parts Assembly[...]

  • Page 35

    OM-233 045 Page 31 Description Part No. Dia. Mkgs. Item No. Figure 8.1. Parts Assembly Quantity 1 +175 148 Wrapper 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 256 Insulator , Side 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 36

    OM-233 045 Page 32 Description Part No. Dia. Mkgs. Item No. Figure 8.1. Parts Assembly (Continued) Quantity 44 Z1 173 570 Stabilizer 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 L1 173 563 Inductor , Input 1 . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 37

    Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.weldin g .or g Star t Y our Professional W eldin g Career Now![...]

  • Page 38

    Notes SOCKET/WRENCH SELECTION T ABLE (U.S. ST ANDARD) SOCKET/WRENCH SELECTION T ABLE (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size Bolt Diameter Decimal Equivalent Bolt Nut Bolt Diameter U.S. Decimal Equivalent Bolt Nut 1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm 5/16 in .3125 in 1/2 in 9/16 in 8 mm [...]

  • Page 39

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe[...]

  • Page 40

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Compan y 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarter s − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX : 920-735-4134 Int ernati onal F AX: 9 20-735-4125 European Headqua rters −[...]