Miller XMT 304 Arc Welder

OM180 BlUE November 1997 Eff. w/SeriaI Number KH391014 Processe* Multiprocess Welding Description

Ce

Owner’S Manual

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. 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. To locate your nearest distributor call 1-800-4-A-Miller.

Iso 9001

Ih~Istereo

I Quality System

1 •800-4-A-Millek

Tig

= Gtaw

= Smaw

Table Of Contents

Section 1

- Safety Precautions

Read Before Using

Section 1

- Consignes De Securite

- Lire Avant Utilisation

Section 2- Definitions

Section 3- Installation

Section 4- Operation

Section 5- Maintenance & Troubleshooting

Section 7- Parts List

War Ranty

Declaration of Conformity For European Community (CE) Products Manufacturer’s Name: Miller Electric Mfg. Co. Manufacturers Address: 1635 W. Spencer Street Appleton, WI 54914 USA Declares that the product XMTfi304 conforms to the following Directives and Standards: Directives Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC Low Voltage Directive: 73/23/EEC Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC Standards Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: December 1995 Safety Requirements for Arc Welding Equipment part 1: EN 60974-1:1989 Degrees of Protection provided by Enclosures (IP code): IEC 529:1989 Insulation coordination for equipment within low-voltage systems: Part 1: Principles, requirements and tests: IEC 664-1:1992 European Contact: Mr. Luigi Vacchini, Managing Director MILLER Europe SPA. Via Privata Iseo 20098 San Giuliano Milanese, Italy Telephone: 39(02)98290-1 Fax: 39(02)98281-552 dec_coni 10/95

Section 1

- Safety Precautions

- Read Before Using

A

A

A

A

• Wearawelding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.l and Z87.1 listed in Safety Standards). • Wear approved safety glasses with side shields under your helmet. • Use protective screens or barners to protect others from flash and glare; warn others not to watch the arc. • Wear protective clothing made from durable, flame-resistant matenal (leather and wool) and foot protection. 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. • Protect yourself and others from flying sparks and hot metal. • Do not weld where flying sparks can strike flammable material. • Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. • Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. • Watch for fire, and keep a fire extinguisher nearby. • Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. • Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.l (see Safety Standards). • Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards. • Do not use welder to thaw frozen pipes. • Remove stick electrode from holder or cut off welding wire at contact tip when not in use. • Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. • Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. MAGNETIC FIELDS can affect pacemakers. • Pacemaker wearers keep away. • Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations. • Wear approved ear protection if noise level is high. CYLINDERS can explode if damaged. Shielding gas 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. • Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. • Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent failing or tipping. • Keep cylinders away from any welding or other electrical circuits. • Never drape a welding torch over a gas cylinder. • Never allow a welding electrode to touch any cylinder. • Never weld on a pressurized cylinder — explosion will result. • Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. • Turn face away from valve outlet when opening cylinder valve. • Keep protective cap in place over valve except when cylinder is in use or connected for use. • Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-i listed in Safety Standards. 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. • Shut off shielding gas supply when not in use. • Always ventilate confined spaces or use approved air-supplied respirator. • Do not touch hot parts bare handed. • Allow cooling period before working on gun or torch. Noise from some processes or equipment can damage hearing. • Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw oft slag. • Wear approved safety glasses with side shields even under your welding helmet. OM-180 670 Page 2

— rgI!~1FM~IU~ aSI

I

D.C. 20402.

F4.1,

Before

Considerations About Welding And The Effects Of Low Frequency

Section 1

- Consignes De Securite

- Lire Avant

Uti Lisation

A

A

A

A

L

Le rayonnement de Parc du procØdØ de soudage genere des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br~lures dans Ies yeux et sur Ia peau. Des Øtlncelles sont projetees pendant le soudage. • Porter un casque de soudage muni d’un Øcran do filtre appropriØ pour protØger votre visage et vos yeux pendant Ie soudage ou pour regar der (voir ANSI Z49.1 et Z87.1 ØnumØrØ dans les normes de sØcuritØ). • Porter des protections approuvØs pour les oreilles Si le niveau sondro ast trap ØlevØ. • Utiliser des Øcrans ou des barriŁres pour proteger des tiers de I’Øclair et de l’eblouissement; demander aux autres personnes de ne pas re garder I’arc. • Porter des vØtements de protection constituØ dans une matiŁre dura ble, resistant au feu (cuir ou lame) et une protection des pieds. r~c~

I

I

L

-~~I

• No pas installer l’apparoil a proximitØ do produits inflammables • No pas surchargor l’installation Øloctriquo — s”assuror quo l’alimon tation ost corroctomont dimonsionnØ ot protØgØ avant do mottro l’apparoil on sorvice. =— 1St!. • Utilisor l’anneau do lovage uniquomont pour sou lovor l’apparoil, NON PAS los chariot, los boutoil los do gaz ou tout autro accessoiro. ____________ • Litilisor un ongin d’une capacitØ appropriØe pour soulovor l’apparoil. • En utilisant dos fourchos do levago pour dØplacor l’unitØ, s’assuror quo los fourchos sont suffisammont longuos pour dØpasser du côtØ oppose do l’apparoil. • Lo rayonnomont haute frequence pout provoquer dos interferences avoc los Øquipoments de ra dio—navigation et do communication, los servicos do sØcuritØ et los ordinatours. • Domandor seulement a dos personnes qualifiØes famillarisØos avec des Øquipements Ølectroniques de faire fonctionner l’installa tion. • L’utilisateur est tenu do faire corrigor rapidoment par un Ølectriclon qualifiØ los interferences resultant de l’installation. • Si 10 FCC signale dos interferences, arrØter immØdiatemont l’appa reil. • Effoctuer rØgulierement le controlo et l’ontrotion do l’installation. • Maintonir soigneusomont fermØs los portes ot los panneaux des sources do haute frequence, maintonir los eclateurs a une distance corrocto et utilisor uno terre ot et un blindage pour rØduiro los inter fØronces Øventuelles. • L’Ønergie electromagnØtiquo risque do provoquer des interferences pour I’Øquipomont electroniquo sensible tel quo los ordinateurs et lequipement commandØ par ordinateur tel quo los robots. • Veiller ace quo tout l’equipement do Ia zone de soudago solt com patible ØlectromagnØtiquement. • Pour rØduire Ia possibilitØ dintorfØrenco, maintonir los cables do soudago aussi courts quo possible, los grouper, et los poser aussi bas quo possible (ox. par torro). • Voiller a soudor a une distance do 100 metros do tout Øqulpomont electroniquo sensible. • Veiller a ce quo co poste de soudage soit pose et mis a Ia torro conformØment a co mode d’omploi. • En cas d’intorfØroncos aprØs avoir pris los mosures prØcØdentes, il incombe a l’utilisateur do prendro dos mosuros supplØmontairos tollos quo lo dØplacemont du posto, l’utilisation do cables blindØs, l’utilisation do filtres do ligno ou Ia pose do protoctours dans Ia zone do travail. • No pas placer I’appareil sur, au-dessus ou a proximitØ do surfacos infliammablos. Rester a l’Øcart dos organes mobiles commo le ventilatour. • Maintenir fermØs et fixoment on place los portos, pannoaux, rocouvrements et dispositifs de protection. • PrØvoir uno pØriode do rofroidissemont, rospoc tor lo cycle opØratoiro nominai. • RØduire lo courant ou le cycle opØratoiro avant do recommancer le soudago. • Ne pas obstruor los passages dair du poste. • Etablir Ia connexion avoc Ia barretto do torro avant do manipulor des cartos ou des piØcos. • Utiliser des pochettos ot des boites antistatiques pour stocker, dØplacor ou expØdior dos cartes do circuits imprimos. ~tES! O?GAN~S1 MppILEs. peuveii,t .aQa ~ktoc(!Ler~Sb’ttI~StJ • No pas s’approchor dos organos mobiles. • No pas s’approchor dos points do coincomont tols quo des rouloaux do commando. i~f*i%~E~1W4~ • No pas appuyer sur Ia gachotto avant d’on avoir roçu linstruction. • No pas dirigor 10 pistolot vors soi, dautros per sonnos ou touto piŁco mØcaniquo on ongagoant lo flu do soudago. Porteurs do stimulateur cardiaque, rostoz a dis tance. • Los porteurs dun stimulatour cardiaquo dolvent d’abord consultor lour mØdocin avant de s’appro chor des operations de soudago a l’arc, do gou goago ou do soudago par points. OM-180 670 Page 7

Safetyin Welding and Cutting, norme ANSI Z49.1, de l’American Wel ding Society, 550 NW. Lejeune Rd, Miami FL 33126 Safetyand Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

Aws F4.1

1R3.

Section 2- Definitions

1 Warning! Watch 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 60 seconds after power is turned off before working on unit, OR 6 Check input capacitor voltage, and be sure it is near 0 before touching any parts. 4196 / / / 1 Warning! Watch Out! There are possible hazards as shown by the symbols. / / 2 When power is applied failed parts can explode or cause other parts to explode. 3 Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.

~! I4L~~H?

2-2. Manufacturer’s Rating Labels For CC/CV Models ~QD~i~!I~E ICE 1EN60974-1 b_ ~ • ~

5A1Ov

400A

36V

X

I

U21

I

I 110V

103 310 A

~Q~I-= Ice 1En60974-1

.......L

5Oa1Ov

400A

X

I

I

U21

L~>

I

T

I

1P23

11 Ov

7A

5A

400A

36V

X

U2

1P23

I 11Ov

7A

103311 A

183 310A

2-4. Symbols And Definitions OM-180 670 Page 12

Owner’S Manual

Form: Om-2806

Section 1

- Installation And Operation

Note ~

Rccs-14

Warning

3-1. Specifications

Section 3- Installation

(Cc/Cv

400 V

Kva

Kw

300A@

I

I

U,

~15O

U)

V

&J

70~5)W

Xduty Cycle

I —‘

Or

3-3. Volt-Ampere Curves OM-180 670 Page 14

3-4. Selecting A Location Dimensions And Weight 87 lb (39.5 kg) 24in 12-1/2 in (318 mmY-..>, 17 in (432 mm) Movement Location Do not move or operate unit where it could tip. 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.

A

Jo

Jo

3-5. Weld Output Terminals And Selecting Cable Sizes 10—60% 60—100% Duty Duty Cycle Cycle 3-6. Remote 14 Receptacle Information

24 Volts Ac

A

B

115 Volts Ac

Output

(Oontp.Ctor)

I

J

Remote

Output

Control

C

E

A/V

Amperage

Voltage

H

F

M

A

I

I

J

I

I

I

I

I

Remote

S-0007-D

St-801 192

Gnd

G

K

3-7. 110 Volt AC Duplex Receptacle (Optional For CC Model) 3-8. Electrical Service Guide

Note ~

S-0092J

3-9. Connecting Input Power Check input voltage available at site. 1 Input And Grounding Conductors 2 Line Disconnect Device Select type and size of overcurrent protection using Section 3-8.

A

A

= Gnd/Pe

Section 4- Operation

St-179 275

I

4-2. Front Panel Controls For CC Model

A/~

St.183 303

4-3. Meter Functions

Note ~

I

I

I

V

A

I

I

I

I

V

A

I

I

Q

V

A

I

I

I

I

Mig(Gmaw)

V

A

I

I

I

(Gmaw-P)

V

A

I Ppp

I

Ppp

F~J

V

A

I

Smaw

V

A

I 80.0

I

I

4-4. Mode Switch Settings

Note ~

J

I ~

(Gtaw)

I

Mig(Gmaw)

(Gmaw-P)

F

F

Smaw

I

4-5. Lift-Arc TIG ~ 4-6. Lift-Arc Trigger Hold TIG ~irt~~ With Process Switch in the Uft-Arc

Tig

I

I

__I

Section 5- Maintenance & Troubleshooting

A

A

St-Bo1 192

5-3. Voltmeter/Ammeter Help Displays All directions are in reference to the front of the unit. Al! cir cuitty referred to is located inside the unit. 1 Help 1 Display Indicates a malfunction in the pri mary power circuit. If this display is shown, contact a Factory Autho rized Service Agent. 2 Help 2 Display Indicates a malfunction in the ther mal protection circuitry located on the left side of the unit, If this dis play is shown, contact a Factory Authorized Service Agent. 3 Help 3 Display Indicates the left side of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 3-2). Operation will contin ue when the unit has cooled. 4 Help 4 Display Indicates a malfunction in the ther mal protection circuitry located on the right side of the unit. If this dis play is shown, contact a Factory Authorized Service Agent. 5 Help 5 Display Indicates the right side of the unit has overheated. The unit has shut down to allow the fan to cool it (see SectIon 3-2). Operation will contin ue when the unit has cooled. 6 Help 6 Display Indicates that the input voltage is too low and the unit has automati cally shut down. Operation will continue when the voltage is within the acceptacle lower range limit (15% below the applicable input voltage). If this display is shown, have an electrician check the input voltage. 7 Help 7 Display Indicates that the input voltage is too high and the unit has automati cally shut down. Operation will continue when the voltage is within the acceptacle upper range limit (15% above the applicable input voltage). If this display is shown, have an electrician check the input voltage.

B

A

I

~1~L~P-4~

~ P~6

A

5-4. Troub’eshooting ‘i~k~H’~ Trouble Remedy No weld output; unit completely mop- erative. Place line disconnect switch In On position (see SectIon 3-9). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-9). Check for proper input power connections (see Section 3-9). No weld output; meter display On. If using remote control, be sure Mode Selector switch Is in a position that provides output control at Remote 14 receptacle. Check, repair, or replace remote control. Unit overheated. Allow unit to cool with fan On (see Section 3-2). Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-5). Clean and tighten all weld connections. No 110 volts ac output at duplex re- ceptacle, Remote 14 receptacle. Reset circuit breaker CB1 (see Section 3-7). No 24 volts ac output at Remote 14 receptacle. Reset circuit breaker CB2 (see Section 3-7). OM-180 670 Page 26

Section 6- Electrical Diagram

Rco-3

Rc5-4

Rc5-9~

F~2-8

I~

Sc-187 147

0 0 0) 0 -u

Cd M 0)

-L

(1)Ti

U’

Figure 7-1. Main Assembly +175 148

.. Wrapper

Handle

.. Connector&Sockets

Connector & Sockets

Connector & Sockets

.. Connector & Sockets

Connector & Sockets

Nu1~ 1.000Npt

Connector & Sockets

Connector & Sockets

Connector & Sockets

Base

Be Sure To Provide Model And Serial Number When Ordering Replacement Parts.

Pc3

Pc3

Plg11

C7,8....

Plg2....

Plg3....

Plg5....

Plg7....

T2

T2

Cb1

Cb1

Cb2

T3

Pc2

Plg12

Plg13

Plg14,15

Fm

Figure 7-2. Center Baffle w/Components

Cm

Cm

Cm

Cm

N

Cm

Cm

Cm

U)

Cm

Cm

Cd

Cm

St-8O1 608-C

Figure 7-2. Center Baffle w/Components (Fig 7-1 Item 22) 181853.. 2 179276.. 3

P06

...9...C5,6R1...175194..

Rt1,2

13.... Pm1,2....

Li

Rc1O

C3,4

Ct1

Rc1

Hd1

Plg9

Windtunnel,Lh

Transformer, Hf

Resistor/Capacitor

Stabilizer

Connector &Sockets

Bracket~ Di/Dt

Coil, Di/Dt

Core

Windtunnel, Rh

Connector&Pins

Be Sure To Provide Model And Serial Number When Ordering Replacement Parts.

Notes __ ________________ __

Umited Warranty

Is Expressly In

Lieu

Of

Express

Or

Implied,

Including

The

Of

Merchantability And Fitness.

Miller Products Are Intended For Purchase

And Use By Commercial/Industrial Users And

Persons Trained And Experienced

In The Use

Provided Herein Are The Sole And Exclusive

Remedies.

In No Event Shall Miller Be Liable

For

Direct,

Indirect,

Special,

Or

Consequential

Damages

(Including

Loss

Of

Profit), Whether Based On Contract, Tort Or

Any Other Legal Theory.

Any Express Warranty Not Provided Herein

And

Any

Implied

Warranty,

Guaranty

Or

Representation As To Performance, And Any

Remedy For Breach Of Contract Tort Or Any

Other

Legal

Theory

Which,

But

For

This

Provision,

Might

Arise

By

Implication,

Operation Of Law, Custom Of Trade Or Course

Of Dealing, Including Any Implied Warranty Of

Merchantability

Or

Fitness

For

Particular

Purpose,

With

Respect

To

Any

And

All

Equipment

Furnished

By

Miller

Is Excluded

And Disclaimed By Miller.

Owoer’s Record Please complete and retain wltb your personal records. Model Nail srlalj$tyle Numbr Purckne lIlt. (Date which equipment was delivered to original customer.) Dlstrl~stsr Address City Stats ZIp Resources Available Always provide Model Name and Serial!Style Number. C oPtic! your Dlstribeter for: To locate distributor nearest you call 1 -800-4-A-Miller. Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, Wi 54914 USA International Headquarters-USA Phone: 414-734-9821 USA & Canada FAX 414-735-4134 International FAX: 414-735-4125 European Headquarters

Fax 44 (0) 1625-537553

Printed In Usa