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OM-2208 Page 1

SECTION 1 

 SAFETY PRECAUTIONS - READ BEFORE USING

som 2018

01

7

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

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.
Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE

 

 Indicates statements not related to personal injury.

.

Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-5. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this equipment. A qualified person is defined as one

who, by possession of a recognized degree, certificate, or

professional standing, or who by extensive knowledge, train-

ing and experience, has successfully demonstrated ability to

solve or resolve problems relating to the subject matter, the

work, or the project and has received safety training to recog-

nize and avoid the hazards involved.

During operation, keep everybody, especially children, away.

Touching live electrical parts can cause fatal shocks

or  severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic

wire welding, the wire, wire reel, drive roll housing,

and all metal parts touching the welding wire are

electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

D

Do not touch live electrical parts.

ELECTRIC SHOCK can kill.

D

Wear dry, hole-free insulating gloves and body protection.

D

Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D

Do not use AC weld output in damp, wet, or confined spaces, or if

there is a danger of falling.

D

Use AC output ONLY if required for the welding process.

D

If AC output is required, use remote output control if present on

unit.

D

Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp

locations or while wearing wet clothing; on metal structures such

as floors, gratings, or scaffolds; 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 equipment in order presented: 1) a

semiautomatic DC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit volt-

age. In most situations, use of a DC, constant voltage wire welder

is recommended. And, do not work alone!

D

Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D

Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

D

Always verify the supply ground 

 check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D

When making input connections, attach proper grounding conduc-

tor first 

 double-check connections.

D

Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D

Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare

wiring can kill.

D

Turn off all equipment when not in use.

D

Do not use worn, damaged, undersized, or repaired cables.

D

Do not drape cables over your body.

D

If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D

Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D

Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

D

Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D

Wear a safety harness if working above floor level.

D

Keep all panels and covers securely in place.

D

Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D

Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D

Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in

use.

D

Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld-

ing power sources AFTER removal of input power.

D

Turn off unit, disconnect input power, and discharge input capaci-

tors according to instructions in Manual before touching any parts.

HOT PARTS can burn.

D

Do not touch hot parts bare handed.

D

Allow cooling period before working on

equipment.

D

To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

Summary of Contents for XMT 304

Page 1: ...60 Volt Model R Processes Description Multiprocess Welding Arc Welding Power Source OM 2208 175493AY 2018 02 File MULTIPROCESS For product information Owner s Manual translations and more visit www Mi...

Page 2: ...ntinue 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...

Page 3: ...ions 9 3 2 Miscellaneous Symbols And Definitions 10 SECTION 4 SPECIFICATIONS 11 4 1 Serial Number And Rating Label Location 11 4 2 Unit Specifications 11 4 3 Dimensions And Weight 11 4 4 Environmental...

Page 4: ......

Page 5: ...lectrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling...

Page 6: ...t possible tightly cover them with approved covers D Do not weld where flying sparks can strike flammable material D Protect yourself and others from flying sparks and hot metal D Be alert that weldin...

Page 7: ...move unit be sure forks are long enough to extend beyond opposite side of unit D Keep equipment cables and cords away from moving vehicles when working from an aerial location D Follow the guidelines...

Page 8: ...orge Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards...

Page 9: ...rant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques...

Page 10: ...La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incen dies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des...

Page 11: ...mettre l appareil en service LA CHUTE DE L QUIPEMENT peut provoquer des blessures D Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout a...

Page 12: ...andard AWS A6 0 from Global EngineeringDocuments phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02169 ph...

Page 13: ...connect power to unit Safe29 2012 05 Disconnect input plug or power before working on machine Safe30 2012 05 5min V V V Hazardous voltage remains on input capacitors after power is turned off Do not t...

Page 14: ...ielded Metal Arc Welding SMAW U1 Primary Voltage IP Degree Of Protection Alternating Current AC Remote Negative Variable Inductance Foot Control Gas Metal Arc Welding GMAW U2 Conventional Load Voltage...

Page 15: ...ambient air temperature up to 1045F 405C Rated Output at 60 Duty Cycle Voltage Range in CV Mode Amperage Range in CC Mode Max Open Circuit Voltage RMS Amps Input at Rated Load Output 60 Hz 3 Phase at...

Page 16: ...55 C Temp_2016 07 6 Minutes Welding 4 Minutes Resting 4 5 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats out...

Page 17: ...pere Curves va_curve1 4 95 SA 178 652 SA 178 653 Volt ampere curves show minimum and maximum voltage and amper age output capabilities of unit Curves of other settings fall be tween curves shown C CC...

Page 18: ...rks Extend forks beyond opposite side of unit 2 Lifting Handles Use handles to lift unit 3 Hand Cart Use cart or similar device to move unit 4 Line Disconnect Device Locate unit near correct input pow...

Page 19: ...95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 2x4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 2x4 0 2x120...

Page 20: ...or the rated output and duty cycle of the welding power source In dedicated circuit installations the National Electrical Code NEC allows the receptacle or conductor rating to be less than the rating...

Page 21: ...OM 2208 Page 17 Notes...

Page 22: ...OM 2208 Page 18 5 6 Connecting 1 Phase Input Power Input1 2012 05 Ref 803 766 C 1 6 5 4 2 7 6 L1 L2 1 GND PE Earth Ground 3 3 1 8 9 10 Tools Needed...

Page 23: ...del can be connected to either 460 or 575 VAC input power See rating label on unit and check input volt age available at site 1 Black And White Input Conductor L1 And L2 2 Red Input Conductor 3 Green...

Page 24: ...OM 2208 Page 20 5 7 Connecting 3 Phase Input Power input2 2012 05 Ref 803 766 C 801 192 GND PE Earth Ground L1 2 1 L2 L3 3 3 4 5 6 7 Tools Needed...

Page 25: ...can be connected to either 230 or 460 VAC in put power A 460 575 model can be con nected to either 460 or 575 VAC input power For Three Phase Operation 1 Input Power Cord 2 Disconnect Device switch sh...

Page 26: ...in Re mote position In most modes remote control is a percent of V A Adjust control setting val ue selected on V A Adjust is maximum avail able on remote In the MIG mode remote control provides full r...

Page 27: ...V A 24 5 85 Stick Actual Volts OCV Preset Amps V A 80 0 85 Actual Volts Actual Amps V A 24 5 85 V Sense Feeder Flashes OCV And Preset Blank V A 80 0 Actual Volts Actual Amps V A 24 5 250 6 3 Mode Swit...

Page 28: ...t between electrode and workpiece The solid state output contactor does not energize until after electrode is touching workpiece This allows electrode to touch workpiece with out overheating sticking...

Page 29: ...OM 2208 Page 25 7 2 Blowing Out Inside Of Unit 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...

Page 30: ...de of the unit has overheated The unit has shut down to allow the fan to cool it see Section 4 5 Operation will continue when the unit has cooled Help 6 Display Indicates that the input voltage is too...

Page 31: ...tput control at Remote 14 receptacle see Section 6 3 Input voltage outside acceptable range of variation see Section 5 5 Check repair or replace remote control Unit overheated Allow unit to cool with...

Page 32: ...OM 2208 Page 28 SECTION 8 ELECTRICAL DIAGRAMS 278447 B Figure 8 1 Circuit Diagram For 230 460 Volt Models...

Page 33: ...OM 2208 Page 29 Notes...

Page 34: ...K Hardware is common and not available unless listed 1 2 3 25 26 27 28 29 37 44 45 46 47 48 51 52 53 54 55 56 19 57 58 59 6 62 11 7 8 9 10 13 14 15 16 17 18 19 20 21 22 23 24 30 31 32 36 38 39 11 40...

Page 35: ...15091 Connector Sockets RC5 1 PLG7 115093 Connector Sockets RC7 1 22 RC10 166679 Connector Sockets 1 23 W1 2 262315 Contactor W Interlock Stand Offs Includes 1 173763 Stand Off No 10 32 x 1 418 8 24 T...

Page 36: ...1 53 129525 Receptacle Twlk Insul Fem 2 53 209219 Receptacle Twlk Insul Fem Tweco 2 54 Nameplate Order By Model And Serial Number 1 55 174992 Knob Pointer 840 2 56 175855 Door Front 1 57 174991 Knob P...

Page 37: ...Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now...

Page 38: ...Notes...

Page 39: ...or Tregaskiss Guns No Labor Water Cooling Systems Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries 6 90 Days Parts Accessory Kits Canvas C...

Page 40: ...h your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equi...

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