Miller Electric OM-193 084E Owner'S Manual Download

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Processes

Multiprocess Welding

OM-193 084E

March 2002

Description

Arc Welding Power Source

XMT 304

(460 Volt Models)

CC/CV and CC Models

Visit our website at

www.MillerWelds.com

Summary of Contents for OM-193 084E

Page 1: ...Processes Multiprocess Welding OM 193 084E March 2002 Description Arc Welding Power Source XMT 304 460 Volt Models R CC CV and CC Models Visit our website at www MillerWelds com ...

Page 2: ... 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 uni...

Page 3: ...s And Definitions 12 SECTION 3 INSTALLATION 13 3 1 Specifications 13 3 2 Duty Cycle And Overheating 13 3 3 Volt Ampere Curves 14 3 4 Selecting A Location 15 3 5 Weld Output Terminals And Selecting Cable Sizes 16 3 6 Remote 14 Receptacle Information 16 3 7 Electrical Service Guide 17 3 8 Connecting Input Power 17 SECTION 4 OPERATION 18 4 1 Front Panel Controls 18 4 2 Meter Functions 19 4 3 Mode Swi...

Page 4: ...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 t...

Page 5: ...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 Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill D Turn off all equipment when not in use D Do not use worn damaged undersized or poorly spliced cables D Do n...

Page 6: ... welding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off sla...

Page 7: ... maintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots D Be sure all equipment in the welding area i...

Page 8: ... is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one s...

Page 9: ...tion est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre D En effectuant les raccordements d entrée fixer d abord le conducteur de mise à la terre approprié et contre vérifier les connexions D Vérifier fréquemment le cordon d alimentation pour voir s il n est pas endommagé ou dénudé remplacer le cordon immédiatement ...

Page 10: ...ct D Porter des vêtements de protection dépourvus d huile tels que des gants en cuir une chemise en matériau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce à...

Page 11: ... dispositifs de protection LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences D Le rayonnement haute frequence peut provoquer des interférences avec les équipements de ra dio navigation et de communication les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l install...

Page 12: ...nétiques basse fréquence Le courant de soudage pendant son passage dans les câbles de sou dage causera des champs électromagnétiques Il y a eu et il y a encore un certain souci à propos de tels champs Cependant après avoir ex aminé plus de 500 études qui ont été faites pendant une période de recherche de 17 ans un comité spécial ruban bleu du National Re search Council a conclu L accumulation de p...

Page 13: ...2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks 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 it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and in...

Page 14: ...parts 7 When power is applied failed parts can explode or cause other parts to explode 8 Flying pieces of parts can cause injury Always wear a face shield when servicing unit 9 Always wear long sleeves and button your collar when servicing unit 10 After taking proper precautions as shown connect power to unit 11 98 1 2 3 4 5 6 7 8 9 10 S 179 309 A 60 1 Warning Watch Out There are possible hazards ...

Page 15: ...OM 193 084 Page 11 2 2 Manufacturer s Rating Labels ...

Page 16: ...trol Line Connection Arc Force Shielded Metal Arc Welding SMAW Gas Metal Arc Welding GMAW Three Phase Static Frequency Con verter Transformer Rectifier U0 Rated No Load Voltage Average U1 Primary Voltage U2 Conventional Load Voltage X Duty Cycle Hz Hertz IP Degree Of Protection I2 Rated Welding Current Percent Pulsed Lift Arc Trigger Hold Operation GTAW Single Phase Three Phase I1max Rated Maximum...

Page 17: ... 9 0 09 11 4 0 04 While idling 6 Minutes Welding 4 Minutes Resting 3 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats output stops a Help message is displayed see Section 5 3 and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle be fore welding Y Exceeding duty cycle can da...

Page 18: ... Ampere Curves va_curve1 4 95 SA 178 652 SA 178 653 Volt amperecurves 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 19: ...ine input power needs 4 Line Disconnect Device Locate unit near correct input power supply Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 24 in 610 mm 17 in 432 mm 12 1 2 in 318 mm Movement 1 1 2 Y Do not move or operate unit where it could tip Location 4 Dimensions And Weight 18 in 460 mm 18 in 460 mm 87 lb 39 5 kg 3 ...

Page 20: ...3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 Output Receptacles 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 600 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 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 S 0007 D 3 6 Remote 14 Receptacle Information Socket Socket Information 24 VOLTS AC A 2...

Page 21: ... Or Circuit Breaker Rating In Amperes 30 Reference 1996 National Electrical Code NEC S 0092J 3 8 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 7 Y Always connect green yel low wire to supply ground ing terminal never to a line terminal Input_9_99 Ref ST 144 221 ST...

Page 22: ...most modes remote control is a percent of the Voltage Amperage Adjustment control setting the value se lected on Voltage Amperage Adjustment control is maximum available on remote In the MIG mode remote control provides full range of unit output regardless of V A Adjust control setting 7 Inductance Dig Control Control adjusts Dig when a Stick SMAW welding position is selected on mode switch When s...

Page 23: ...c is broken NOTE Mode Meter Reading At Idle Lift Arc Trigger Hold TIG GTAW V A Blank Preset Amps 85 TIG GTAW Blank Preset Amps V A 85 MIG GMAW Preset Volts Blank V A 24 5 Pulsed MIG GMAW P Pulse Display Pulse Display V A PPP PPP Remote Control SMAW Blank Preset Amps V A 85 Panel Control SMAW Actual Volts OCV Preset Amps V A 80 0 85 ...

Page 24: ...rode sticking at arc start NOTE Mode Output Control Lift Arc Trigger Hold TIG GTAW Select or Amp Requires Control TIG GTAW With HF Unit Pulsing Device Or Remote Control Select or Amp Requires Control MIG GMAW Select or Volt Requires Feeder Pulsed MIG GMAW P Requires an external pulsing device Select Volt Requires Feeder or Control Remote Control SMAW Select or Amp Requires Control Panel Control SM...

Page 25: ...tput switch Slowly lift electrode An arc will form when electrode is lifted To stop welding momentarily depress output switch and out put will shut off 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 1 1 2 Seconds Touch Do NOT Strike Like A Match 2 Ref S 156 279 control ...

Page 26: ...ths 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 Months Blow Out Inside 5 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 ...

Page 27: ...t side of the unit has over heated The unit has shut down to allow the fan to cool it see Section 3 2 Operation will continue when the unit has cooled 7 Help 6 Display Indicates that the input voltage is too low and the unit has automatically shut down Opera tion will continue when the voltage is within the acceptable lower range limit 15 below the applicable input voltage If this display is shown...

Page 28: ...s if necessary or reset circuit breaker see Section 3 8 Check for proper input power connections see Section 3 8 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 outpu...

Page 29: ...OM 193 084 Page 25 SECTION 6 ELECTRICAL DIAGRAM 197 552 Figure 6 1 Circuit Diagram For Welding Power Source ...

Page 30: ...OM 193 084 Page 26 SECTION 7 PARTS LIST 802 500 B Figure 7 1 Main Assembly ...

Page 31: ...0 1 21 PLATE ident rear order by model and serial number 1 22 175 138 BOX louver 2 23 192 853 BRACKET mtg contactor capacitor PC Board 1 24 PC1 202 763 CIRCUIT CARD control 1 PLG2 131 056 CONNECTOR SOCKETS 1 PLG3 130 203 CONNECTOR SOCKETS 1 PLG5 115 091 CONNECTOR SOCKETS 1 PLG7 115 093 CONNECTOR SOCKETS 1 25 RC10 166 679 CONNECTOR SOCKETS 1 26 T2 192 743 TRANSFORMER control 460VAC 1 27 183 549 BRA...

Page 32: ...ERMINAL connector friction 2 55 C7 8 186 543 CAPACITOR cer disc 1uf 500VDC 2 56 185 732 PANEL front 1 57 129 525 RECEPTACLE twlk insul fem 2 58 NAMEPLATE order by model and serial number 1 59 174 992 KNOB pointer 840 2 60 175 855 DOOR front 1 61 174 991 KNOB pointer 1 250 2 62 176 226 INSULATOR switch power 1 63 S1 128 756 SWITCH tgl 3PST 40A 600VAC 1 64 179 310 LABEL warning general precautionary...

Page 33: ...OM 193 084 Page 29 Notes ...

Page 34: ...OM 193 084 Page 30 Notes ...

Page 35: ...utting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These item...

Page 36: ... complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Informati...

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