Miller XMT 304 Technical Manual
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Miller XMT 304 Technical Manual

Multiprocess welding
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See also: Owner's Manual
TM-180 670B
September 2001
Eff. w/Serial Number KG139511
Processes
Multiprocess Welding
Description
Arc Welding Power Source
R
XMT 304
(400 Volt Models)
Visit our website at
www.MillerWelds.com

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Summary of Contents for Miller XMT 304

  • Page 1 TM-180 670B September 2001 Eff. w/Serial Number KG139511 Processes Multiprocess Welding Description Arc Welding Power Source XMT 304 (400 Volt Models) Visit our website at www.MillerWelds.com...
  • Page 2 Declaration of Conformity For European Community (CE) Products Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA XMT 304 Declares that the product: conforms to the following Directives and Standards: Directives Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING ........WARNING 1-1.

  • Page 5: Section 1 - Safety Precautions For Servicing

    D Do not place unit on, over, or near combustible D Keep away from moving parts such as fans. surfaces. D Keep all doors, panels, covers, and guards D Do not service unit near flammables. closed and securely in place. XMT 304 TM-180 670 Page 1...

  • Page 6: Emf Information

    OVER- READ INSTRUCTIONS. HEATING. D Use MILLER Testing Booklet (Part No. 150 D Allow cooling period; follow rated duty cycle. 853) when servicing this unit. D Reduce current or reduce duty cycle before D Consult the Owner’s Manual for welding safety starting to weld again.

  • Page 7: Section 2 - Definitions

    Wear complete body protection. Become trained and read the instructions before working on the machine or welding. Do not remove or paint over (cover) the label. S-179 310 1/96 XMT 304 TM-180 670 Page 3...
  • Page 8 Keep angle of lifting device less than 60 degrees. ∠ = <60 ° Use a proper cart to move unit. ∠ Do not use one handle to lift or support unit. S-179 309-A 1/96 TM-180 670 Page 4 XMT 304...

  • Page 9: Manufacturer's Rating Labels

    2-2. Manufacturer’s Rating Labels XMT 304 TM-180 670 Page 5...

  • Page 10: Symbols And Definitions

    Load Voltage Degree Of Rated Welding Hertz Percent Protection Current Lift-Arc Trigger Pulsed Hold Operation Single Phase Three Phase (GTAW) Rated Maximum Maximum Effective Lift-Arc Operation Increase 1max 1eff Supply Current Supply Current (GTAW) TM-180 670 Page 6 XMT 304...

  • Page 11: Section 3 - Installation

    Reduce amperage or duty cycle be- fore welding. Y Exceeding duty cycle can damage unit and void war- ranty. 60% Duty Cycle 6 Minutes Welding 4 Minutes Resting Overheating Reduce Duty Cycle Minutes Ref. SA-178 651 XMT 304 TM-180 670 Page 7...

  • Page 12: Volt-Ampere Curves

    Curves of other settings fall be- tween curves shown. A. CC Mode B. CV Mode ARC CONTROL va_curve1 4/95 – SA-178 652 / SA-178 653 TM-180 670 Page 8 XMT 304...

  • Page 13: Selecting A Location

    Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Location Section 20. 18 in (460 mm) 18 in (460 mm) loc_2 3/96 - ST-801 192 XMT 304 TM-180 670 Page 9...

  • Page 14: Weld Output Terminals And Selecting Cable Sizes

    *Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. **( ) = mm for metric use. S-0007-E TM-180 670 Page 10 XMT 304...

  • Page 15: Remote 14 Receptacle Information

    CB1 protects 110 volt ac portion of duplex receptacle and Remote 14 receptacle from overload. CB2 protects 24 volt ac portion of Remote receptacle from overload. Press button to reset breaker. Ref. ST-801 245-A XMT 304 TM-180 670 Page 11...

  • Page 16: Electrical Service Guide

    Y Always connect grounding terminal. conductor first. = GND/PE Green/Yellow Install conductors into a deenergized line dissconnect device. Tools Needed: Input_9_99 / Ref. ST-144 221 / ST-801 192 TM-180 670 Page 12 XMT 304...

  • Page 17: Section 4 - Operation

    For Air Carbon Arc (CAC-A) cutting and Control adjusts Dig when a Stick (SMAW) processes is selected, this control is not func- gouging, place switch in Stick position. For welding position is selected on mode switch. tional. XMT 304 TM-180 670 Page 13...

  • Page 18: Meter Functions

    (GMAW-P) Pulse Display Pulse Display Actual Volts Actual Amps Remote 24.5 Control SMAW Blank Preset Amps Actual Volts Actual Amps Panel Control 85.0 24.5 SMAW Actual Volts (OCV) Preset Amps Actual Volts Actual Amps TM-180 670 Page 14 XMT 304...

  • Page 19: Mode Switch Settings

    Or Remote Control Requires: Control Select: Volt MIG (GMAW) Requires: Feeder Pulsed MIG Select: Volt (GMAW-P) (Requires an external pulsing device.) Requires: Feeder or Control Select: Remote Control SMAW Requires: Control Select: Panel Control SMAW Weld XMT 304 TM-180 670 Page 15...

  • Page 20: Lift-Arc Trigger Hold Tig

    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 TM-180 670 Page 16 XMT 304...
  • Page 21 Notes XMT 304 TM-180 670 Page 17...

  • Page 22: Section 5 - Theory Of Operation

    Control R44 (CC Models) In CV mode, R44 functions as an in- ductance control modifying the re- Voltage/ sponse of the arc. In CC mode, R44 Amperage Mode Switch functions as a dig control. Control Switch S2 TM-180 670 Page 18 XMT 304...
  • Page 23 AC Or DC Control Circuits Provides weld or secondary current feedback signal to PC1. φ 30 Positive (+) And Negative (–) Power Weld Output Receptacles Provide weld output and allow changing of output polarity. Weld Current Circuit XMT 304 TM-180 670 Page 19...

  • Page 24: Section 6 - Explanation Of Electrical Parts

    (sometimes referred to as a wiper). Their primary purpose is to give the operator VARIABLE a way to adjust welding parameters such as wire speed, preflow time, voltage, inductance, etc. TM-180 670 Page 20 XMT 304...
  • Page 25 When the inductor is placed in an AC circuit it is referred to as a reactor where it now acts to restrict the flow of current. A “tapped reactor” is used to create current ranges for welding. XMT 304 TM-180 670 Page 21...
  • Page 26 (Notice the “jumper link” connecting terminals A and B together.) SWITCH A mechanical device that completes or SPST SPDT breaks the path of the current or sends it over a different path. DPST DPDT TM-180 670 Page 22 XMT 304...
  • Page 27 Its main use in engine-driven equipment is to activate the “Automatic Idle” circuit by sensing welding current or auxiliary power current. XMT 304 TM-180 670 Page 23...

  • Page 28: Section 7 - Pre-Power Checklist

    If resistance is less than 100 ohms, isolate diodes D1 and D2 and retest individually (diode test). – Weld Output Receptacles Test Equipment Needed: Diodes D1, D2 Ref. SD-183 484 / ST-801 705 TM-180 670 Page 24 XMT 304 XMT 304...

  • Page 29: Input Rectifier Sr1

    (+) and gate terminals. Resistance should be approximately 35 ohms. Negative (–) If results are in doubt, use an IGBT tester (MILLER Part No. – 043 553) to test the SCR portion of SR1 as follows: AC (L1) SCR (–) A.

  • Page 30: Igbt Modules Pm1, Pm2

    PLG5-6 and E2 to PLG5-9 for 100 k ohms ±10% (ohms position) on PM2. IGBT Board If results are in doubt, use an PC4 Or PC5 IGBT tester (MILLER Part No. 043 553) as follows: A. Check two IGBT’s per G2 (B2) G1 (B1) module.

  • Page 31: Diodes

    (diode test). Effective with Serial No. KK276107, these diodes are no longer present. Previous Previous Location Of Location Of Diode D3 Diode D4 Diode Diode Interconnecting Board PC2 ST-801 550 / 195 587 XMT 304 XMT 304 TM-180 670 Page 27...

  • Page 32: Section 8 - Troubleshooting

    SECTION 8 – TROUBLESHOOTING 8-1. Troubleshooting Table See Section 8-4 or 8-5 for test points and values and Section 11 for parts location. Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit. Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 3-9).
  • Page 33 Reduce gas flow rate. Tungsten electrode oxidizing and not Shield weld zone from drafts. remaining bright after conclusion of weld. Increase postflow time. Check and tighten all gas fittings. Water in torch. Refer to torch manual. XMT 304 TM-180 670 Page 29...

  • Page 34: Voltmeter/Ammeter Help Displays Prior To Serial No. Kg150087

    Help 6 Display Indicates a malfunction in the sec- HE.L P–5 ondary power circuit of the unit. If this display is shown, check control board PC1 (see Section 8-7). HE.L P–6 TM-180 670 Page 30 XMT 304...

  • Page 35: Voltmeter/Ammeter Help Displays Effective With Kg150087

    (15% below right side of the unit. If this display is shown, Indicates the left side of the unit has over- the applicable input voltage). If this display is check thermistor RT1. XMT 304 TM-180 670 Page 31...

  • Page 36: Troubleshooting Circuit Diagram For Welding Power Source Prior To Kk104771

    See Section 5 for PC6 information See Section 5 for PC4 information See Section 8-7 See Section 8-9 for for PC1 data RT1, RT2 information See Section 3-6 for RC1 information See Section 8-9 for PC3 data TM-180 670 Page 32 XMT 304...
  • Page 37 1.5 volts dc per 100 amperes of weld output –15 volts dc 87 volts dc open-circuit voltage See Section 5 for PC5 information V15, A, B See Section 8-6 for waveforms A, B SC-181 838-C XMT 304 TM-180 670 Page 33...

  • Page 38: Troubleshooting Circuit Diagram For Welding Power Source Eff. With Kk104771

    See Section 5 for PC6 information See Section 5 for PC4 information See Section 8-7 for PC1 data See Section 8-9 for RT1, RT2 information See Section 3-6 for RC1 See Section 8-9 information for PC3 data TM-180 670 Page 34 XMT 304...
  • Page 39 1 volt dc per 100 amperes of weld output –15 volts dc +15 volts dc 87 volts dc open-circuit voltage See Section 5 for PC5 information V15, A, B See Section 8-6 for waveforms A, B SC-197 552 XMT 304 TM-180 670 Page 35...

  • Page 40: Waveforms For Sections 8-4 And 8-5

    8-6. Waveforms For Sections 8-4 And 8-5 10 µs 20 V 10 µs 20 V A. CC Or CV Mode, DC Open-Circuit Voltage B. CC Or CV Mode, 25 Volts DC, 200 Amperes (Resistive Load) Test Equipment Needed: TM-180 670 Page 36 XMT 304...

  • Page 41: Control Board Pc1 Testing Information (All Models - Use With Section 8-8)

    See Section 8-8 for specific values during testing. Control Board PC1 Receptacle RC1 Receptacle RC2 Receptacle RC3 Receptacle RC5 Receptacle RC6 Receptacle RC7 Receptacle RC8 Receptacle RC9 Test Equipment Needed: ST-801 550 / SC-182 085 XMT 304 TM-180 670 Page 37...

  • Page 42: Control Board Pc1 Test Point Values (All Models)

    18 volts ac input with respect to pin RC2-5 (Prior to KK104771) Not used (Effective w/KK104771) +24 volts dc output (Prior to KK104771) Not used (Effective w/KK104771) Circuit common (Prior to KK104771) 18 volts ac input with respect to pin RC2-11 (Effective w/KK104771) TM-180 670 Page 38 XMT 304...
  • Page 43 Prior to Serial No. KG150087, not used; effective with Serial No. KG150087, negative (–) voltage feedback input with respect to pin RC9-3 Not used Prior to Serial No. KG150087, not used; effective with Serial No. KG150087, positive (+) voltage feed- back input with respect to pin RC9-1 XMT 304 TM-180 670 Page 39...

  • Page 44: Display Board Pc3 Testing Information (All Models - Use With Section 8-10)

    10 Mode Switch S3 Ammeter A Display Board PC3 11 Voltage/Amperage Control Switch S2 Receptacle RC1 No calibration available for voltmeter V (CC/CV Model) Or Amperage Control Receptacle RC2 or ammeter A. Switch S2 (CC Model) TM-180 670 Page 40 XMT 304...

  • Page 45: Display Board Pc3 Test Point Values (All Models)

    +1 volt dc output per 10 volts dc of weld output 0 to +10 volts dc input command signal from min to max of remote control 1, 2 Approximately 33 k ohms at 68°F (20°C) 1, 2 Approximately 33 k ohms at 68°F (20°C) XMT 304 TM-180 670 Page 41...

  • Page 46: Interconnecting Board Pc2 Testing Information (All Models)

    26 in-lb when servicing IGBT’s PM1 and PM2. No test point values provided for this PC board. Interconnecting Board PC2 Receptacle RC1 Receptacle RC2 Receptacle RC3 Test Equipment Needed: ST-801 550 / 195 587 TM-180 670 Page 42 XMT 304...

  • Page 47: Section 9 - Maintenance

    Blow Out Inside 9-2. Blowing Out Inside Of Unit Y Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown. ST-801 192 XMT 304 TM-180 670 Page 43...

  • Page 48: Measuring Input Capacitor Voltage

    Measure the dc voltage across the positive (+) and negative (–) terminals until voltage drops to near 0 (zero) volts. Proceed with job inside unit. Reinstall case when finished. Tools Needed: 5/16 in ST-801 550 TM-180 670 Page 44 XMT 304...

  • Page 49: Checking Bus Voltage Imbalance

    Turn off unit and wait for voltage to drop to near 0 (zero) volts accord- ing to Section 9-3. Prior to Serial No. KK266150, reconnect plug 12 to receptacle 3. Reinstall case. Tools Needed: 5/16 in ST-801 523-A / ST-801 536 XMT 304 TM-180 670 Page 45...

  • Page 50: Section 10 - Electrical Diagrams

    The following is a list of all diagrams for models covered by this manual. To order a copy, proceed as follows: Model Serial Or Style Number Circuit Diagram Wiring Diagram XMT 304 KG139511 thru KG150086 SC-179 690 SD-179 691 KG150087 thru KK104770...
  • Page 51 SC-179 690 Figure 10-1. Circuit Diagram For XMT 304 Effective With Serial No. KG139511 Thru KG150086 XMT 304 TM-180 670 Page 47...
  • Page 52 SC-181 838-C Figure 10-2. Circuit Diagram For XMT 304 Effective With Serial No. KG150087 Thru KK104770 TM-180 670 Page 48 XMT 304...
  • Page 53 197 552 Figure 10-3. Circuit Diagram For XMT 304 Effective With Serial No. KK104771 And Following XMT 304 TM-180 670 Page 49...
  • Page 54 Figure 10-4. Wiring Diagram For XMT 304 Effective With Serial No. KG139511 Thru KK104770 TM-180 670 Page 50 XMT 304...
  • Page 55 SD-179 691 XMT 304 TM-180 670 Page 51...
  • Page 56 Figure 10-5. Wiring Diagram For XMT 304 Effective With Serial No. KK104771 And Following TM-180 670 Page 52 XMT 304...
  • Page 57 SD-195 874 XMT 304 TM-180 670 Page 53...
  • Page 58 Figure 10-6. Circuit Diagram For Control Board PC1 Effective With Serial No. KK104771 And Following (Part 1 Of 3) TM-180 670 Page 54 XMT 304...
  • Page 59 SD-193 758 (1 Of 3) XMT 304 TM-180 670 Page 55...
  • Page 60 Figure 10-7. Circuit Diagram For Control Board PC1 Effective With Serial No. KK104771 And Following (Part 2 Of 3) TM-180 670 Page 56 XMT 304...
  • Page 61 SD-193 758 (2 Of 3) XMT 304 TM-180 670 Page 57...
  • Page 62 Figure 10-8. Circuit Diagram For Control Board PC1 Effective With Serial No. KK104771 And Following (Part 3 Of 3) TM-180 670 Page 58 XMT 304...
  • Page 63 SD-193 758 (3 Of 3) XMT 304 TM-180 670 Page 59...
  • Page 64 Figure 10-9. Circuit Diagram For Display Board PC3 (CC Models) Effective With Serial No. KH523189 And Following TM-180 670 Page 60 XMT 304...
  • Page 65 SD-190 712 XMT 304 TM-180 670 Page 61...
  • Page 66 Figure 10-10. Circuit Diagram For Display Board PC3 (CC/CV Models) Effective With Serial No. KH357827 And Following TM-180 670 Page 62 XMT 304...
  • Page 67 SD-190 709 XMT 304 TM-180 670 Page 63...
  • Page 68 SB-195 589 Figure 10-11. Circuit Diagram For Interconnecting Board PC2 Effective With Serial No. KK276103 And Following 188 015 Figure 10-12. Circuit Diagram For IGBT Boards PC4, PC5 Effective With Serial No. KH391020 And Following TM-180 670 Page 64 XMT 304...
  • Page 69 SA-186 775 Figure 10-13. Circuit Diagram For Filter Board PC6 Effective With Serial No. KH391015 And Following XMT 304 TM-180 670 Page 65...
  • Page 70 Notes TM-180 670 Page 66 XMT 304...
  • Page 71 TM-180 670B September 2001 Processes Multiprocess Welding Description Arc Welding Power Source XMT 304 (400 Volt Models) Eff w/KG139511 And Following For OM-180 670 Revisions * Thru M Visit our website at www.MillerWelds.com...

  • Page 72: Section 11 - Parts List For Kg139511 And Following

    SECTION 11 – PARTS LIST FOR KG139511 AND FOLLOWING 801 605-E Figure 11-1. Parts Assembly TM-180 670 Page 68 XMT 304...
  • Page 73 CAPACITOR, polyp film .5uf 900VDC ......XMT 304 TM-180 670 Page 69...
  • Page 74 *Prior to LB088400, individual seven segments can be replaced with Part No.186 914. Effective w/LB088400, displays are soldered in and not replaceable. Replace with proper PCB assembly. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. TM-180 670 Page 70 XMT 304...
  • Page 78 Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 European Headquarters – United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066  PRINTED IN USA 2001 Miller Electric Mfg. Co.

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