Miller XMT 304 Manuel utilisateur

Processes

Multiprocess Welding

TM-180 670B September2001

Eff. w/Serial Number KG139511

Description

Arc Welding Power Source

XMT 304

(400 Volt Models)

Visit our website at

www.MillerWelds.com

dec_con1 10/95

Declaration of Conformity For

European Community (CE) Products

Manufacturer’s Name: Miller Electric Mfg. Co.

Manufacturer’s Address: 1635 W. Spencer Street

Appleton, WI 54914 USA

Declares that the product: XMT304

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: Danilo Fedolfi, Managing Director

MILLER Europe S.r.l.

Via Privata Iseo

20098 San Giuliano

Milanese, Italy

Telephone: 39(02)98290-1

Fax: 39(02)98281-552

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Servicing Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – DEFINITIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Manufacturer’s Warning Label Definitions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Manufacturer’s Rating Labels 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Symbols And Definitions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Duty Cycle And Overheating 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Volt-Ampere Curves 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Selecting A Location 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Weld Output Terminals And Selecting Cable Sizes 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Remote 14 Receptacle Information 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. 110 Volt AC Duplex Receptacle 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Electrical Service Guide 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Connecting Input Power 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Front Panel Controls 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Meter Functions 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Mode Switch Settings 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Lift-Arc Trigger Hold TIG 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – THEORY OF OPERATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – EXPLANATION OF ELECTRICAL PARTS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – PRE-POWER CHECKLIST 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Checking Unit Before Applying Power 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Output Diodes D1, D2 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Input Rectifier SR1 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Tank Capacitor C1 and Input Capacitors C3, C4 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. IGBT Modules PM1, PM2 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Diodes D1, D2, D3, D4 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – TROUBLESHOOTING 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Troubleshooting Table 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Voltmeter/Ammeter Help Displays Prior To Serial No. KG150087 30. . . . . . . . . . . . . . . . . . . . . .

8-3. Voltmeter/Ammeter Help Displays Effective With KG150087 31. . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Troubleshooting Circuit Diagram For Welding Power Source Prior To KK104771 32. . . . . . . . .

8-5. Troubleshooting Circuit Diagram For Welding Power Source Eff. With KK104771 34. . . . . . . .

8-6. Waveforms For Sections 8-4 And 8-5 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Control Board PC1 Testing Information (All Models – Use With Section 8-8) 37. . . . . . . . . . . . .

8-8. Control Board PC1 Test Point Values (All Models) 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-9. Display Board PC3 Testing Information (All Models – Use With Section 8-10) 40. . . . . . . . . . .

8-10. Display Board PC3 Test Point Values (All Models) 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-11. Interconnecting Board PC2 Testing Information (All Models) 42. . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – MAINTENANCE 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Routine Maintenance 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Blowing Out Inside Of Unit 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Measuring Input Capacitor Voltage 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Checking Bus Voltage Imbalance 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – ELECTRICAL DIAGRAMS 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 – PARTS LIST FOR KG139511 AND FOLLOWING 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARNING

This product, when used

for welding or cutting,

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.)

TM-180 670 Page 1XMT 304

SECTION 1 –SAFETY PRECAUTIONS FOR SERVICING

1-1. Symbol Usage

OM-180 670M - 1/00, safety_stm 5/97

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

YMarks a special safety message.

.Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consultsymbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Servicing Hazards

YThe 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.

YOnly qualified persons should service, test, maintain, and re-

pair this unit.

YDuring servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

DDo not touch live electrical parts.

DTurn Off welding power source and wire feeder

and disconnect and lockout input power using

linedisconnect switch, circuit breakers, or by removing plug from re-

ceptacle,or stop engine before servicing unless the procedure spe-

cifically requires an energized unit.

DInsulateyourself from ground by standing or working on dry insulat-

ing mats big enough to prevent contact with the ground.

DDo not leave live unit unattended.

DIf this procedure requires an energized unit, have only personnel

familiarwith and following standard safety practices do the job.

DWhentesting a live unit, use the one-hand method. Do not put both

hands inside unit. Keep one hand free.

DDisconnect input power conductors from deenergized supply line

BEFORE moving a welding power source.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

DTurn Off inverter, disconnect input power, and discharge input

capacitorsaccording to instructions in Maintenance Section before

touchingany parts.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling

boards or parts.

DUse proper static-proof bags and boxes to

store, move, or ship PC boards.

FIRE OR EXPLOSION hazard.

DDo not place unit on, over, or near combustible

surfaces.

DDo not service unit near flammables.

FLYING METAL can injure eyes.

DWear safety glasses with side shields or face

shield during servicing.

DBe careful not to short metal tools, parts, or

wires together during testing and servicing.

HOT PARTS can cause severe burns.

DDo not touch hot parts bare handed.

DAllowcooling period before working on welding

gun or torch.

EXPLODING PARTS can cause injury.

DFailedparts can explode or cause other parts to

explodewhen power is applied to inverters.

DAlways wear a face shield and long sleeves

when servicing inverters.

SHOCK HAZARD from testing.

DTurn Off welding power source and wire feeder

or stop engine before making or changing me-

ter lead connections.

DUse at least one meter lead that has a self-

retainingspring clip such as an alligator clip.

DRead instructions for test equipment.

FALLING UNIT can cause injury.

DUse lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

DUse equipment of adequate capacity to lift and

supportunit.

DIf using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

MOVING PARTS can cause injury.

DKeep away from moving parts such as fans.

DKeep all doors, panels, covers, and guards

closed and securely in place.

TM-180 670 Page 2 XMT 304

MOVING PARTS can cause injury.

DKeep away from moving parts.

DKeep away from pinch points such as drive

rolls.

MAGNETIC FIELDS can affect pacemak-

ers.

DPacemakerwearers keep away from servicing

areas until consulting your doctor.

OVERUSE can cause OVER-

HEATING.

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before

startingto weld again.

DDo not block or filter airflow to unit.

H.F. RADIATION can cause interference.

DHigh-frequency(H.F.) can interfere with radio

navigation, safety services, computers, and

communicationsequipment.

DHave only qualified persons familiar with

electronicequipment install, test, and service

H.F. producing units.

DThe user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

DIf notified by the FCC about interference, stop using the

equipmentat once.

DHave the installation regularly checked and maintained.

DKeephigh-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimizethe possibility of interference.

READ INSTRUCTIONS.

DUse MILLER Testing Booklet (Part No. 150

853) when servicing this unit.

DConsultthe Owner’s Manual for welding safety

precautions.

DUse only genuine MILLER replacement parts.

1-3. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Weldingcurrent, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields 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

weldingor 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 side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Pacemakers:

Pacemakerwearers consult your doctor first. If cleared by your doctor,

thenfollowing the above procedures is recommended.

TM-180 670 Page 3XMT 304

SECTION 2 –DEFINITIONS

2-1. Manufacturer’s Warning Label Definitions

Warning! Watch Out! There are

possible hazards as shown by the

symbols.

1 Electric shock from welding

electrode or wiring can kill.

1.1 Wear dry insulating gloves.

Do not touch electrode with

bare hand. Do not wear wet or

damaged gloves.

1.2 Protect yourself from electric

shock by insulating yourself

from work and ground.

1.3 Disconnect input plug or

power before working on

machine.

2 Breathing welding fumes can

be hazardous to your health.

2.1 Keep your head out of the

fumes.

2.2 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

injure skin.

4.1 Wear hat and safety glasses.

Use ear protection and button

shirt collar. Use welding

helmet with correct shade of

filter. Wear complete body

protection.

5 Become trained and read the

instructions before working on

the machine or welding.

6 Do not remove or paint over

(cover) the label.

1/96

1 1.1 1.2 1.3

3 3.1 3.2 3.3

4 4.1 +

2 2.1 2.2

2.3

S-179 310

TM-180 670 Page 4 XMT 304

> 60 s

S-179 190-A

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.

4/96

1234 5 6

S-179 304-A

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.

4 Always wear long sleeves and

button your collar when

servicing unit.

5 After taking proper

precautions as shown,

connect power to unit.

4/96

123 4 5

S-179 309-A

∠= <60°

∠

1 Warning! Watch Out! There

are possible hazards as

shown by the symbols.

2 Falling equipment can cause

injury and damage to unit.

3 Always lift and support unit

using both handles. Keep

angle of lifting device less

than 60 degrees.

4 Use a proper cart to move

unit.

5 Do not use one handle to lift

or support unit.

1/96

2345

TM-180 670 Page 5XMT 304

2-2. Manufacturer’s Rating Labels

TM-180 670 Page 6 XMT 304

2-3. Symbols And Definitions

AAmperage Panel Alternating

Current(AC) VVoltage

Output Circuit Breaker Remote On

Off Gas Tungsten Arc

Welding Negative Voltage Input

Direct Current

(DC) Positive Inductance Protective Earth

(Ground)

Constant Current Constant Voltage Foot Control Line Connection

Arc Force Shielded Metal Arc

Welding (SMAW) Gas Metal Arc

Welding (GMAW)

Three Phase Static

Frequency Con-

verter-

Transformer-

Rectifier

U0Rated No Load

Voltage (Average) U1Primary Voltage U2Conventional

Load Voltage XDuty Cycle

Hz Hertz IP Degree Of

Protection I2Rated Welding

Current %Percent

Pulsed Lift-Arc Trigger

Hold Operation

(GTAW) Single Phase Three Phase

I1max Rated Maximum

Supply Current I1eff Maximum Effective

Supply Current Increase Lift-Arc Operation

(GTAW)

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