Instruction/ maintenance manual of the product OM-193 084E Miller Electric
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Processes Multiprocess W elding OM-193 084E March 2002 Description Arc Welding Power Source XMT 304 (460 V olt Models) R CC/CV and CC Models Visit our website at www.
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 orindividual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
The following terms are used interchangeably throughout this manual: TIG = GT A W Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . .
dec_con1 10/95 Declaration of Conformity For European Community (CE) Products Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W .
OM-193 084 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message.
OM-193 084 Page 2 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. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.
OM-193 084 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit.
OM-193 084 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields.
OM-193 084 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives.
OM-193 084 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage.
OM-193 084 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables.
OM-193 084 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American Wel- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.
OM-193 084 Page 9 SECTION 2 – DEFINITIONS 2-1. Manufacturer ’ s W arning Label Definitions W arning! W atch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 1.1 W ear dry insulating gloves.
OM-193 084 Page 10 S-185 836 > 60 s V V V 1 W arning! W atch 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.
OM-193 084 Page 1 1 2-2. Manufacturer ’ s Rating Labels.
OM-193 084 Page 12 2-3. Symbols And Definitions A Amperage Panel Alternating Current (AC) V V oltage Output Circuit Breaker Remote On Of f Gas Tungsten Arc W elding Negative V oltage Input Direct Curr.
OM-193 084 Page 13 SECTION 3 – INST ALLA TION 3-1. Specifications Rated W elding Output V oltage Range (CC/CV Amperage Range Maximum Open-Circuit IP Rating Amperes Input at Rated Load Output 50/60 Hz Output Models Only) Range V oltage DC 460 V KV A KW 300 A @ 32 V olts DC, 60% Duty Cycle 10 – 35 5 – 400 90 23 18.
OM-193 084 Page 14 3-3. V olt-Ampere Curves va_curve1 4/95 – SA-178 652 / SA-178 653 V olt-ampere curves 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.
OM-193 084 Page 15 3-4. Selecting A Location loc_2 3/96 - ST -801 192 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 .
OM-193 084 Page 16 3-5. W eld Output T erminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. T o reduce possible interference, keep weld cables as short as possible, close together , and down low , such as on the floor .
OM-193 084 Page 17 3-7. Electrical Service Guide Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not be available. NOTE Input V oltage 460 Input Amperes At Rated Output 18.
OM-193 084 Page 18 SECTION 4 – OPERA TION 4-1. Front Panel Controls 1 Power On/Off Switch . The fan motor is thermostatically controlled and only runs when cooling is needed.
OM-193 084 Page 19 4-2. Meter Functions The meters display the actual weld output values for approximately three seconds after the arc is broken. NOTE Mode Meter Reading At Idle Lift-Arc T rigger Hold TIG (GT A W) VA Blank Preset Amps 85 TIG (GT A W) Blank Preset Amps VA 85 MIG (GMAW) Preset V olts Blank VA 24.
OM-193 084 Page 20 4-3. Mode Switch Settings The SMAW modes provide the Adaptive Hot Start feature, which automatically increases the output amperage at the start of a weld should the start require it. This eliminates electrode sticking at arc start.
OM-193 084 Page 21 4-4. Lift-Arc T rigger Hold TIG 1 TIG Electrode 2 W orkpiece . Procedure requires: Start sequence: • T ouch tungsten electrode to workpiece at weld start point. • Momentarily depress output switch. • Slowly lift electrode. An arc will form when electrode is lifted.
OM-193 084 Page 22 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions.
OM-193 084 Page 23 5-3. V oltmeter/Ammeter Help Displays . Al l directions are in reference to the front of the unit. All circuitry referred to is lo- cated inside the unit. 1 Help 0 Display Indicates a shorted thermistor RT2 on the left side o f t h e unit.
OM-193 084 Page 24 5-4. Circuit Breakers CB1 And CB2 Ref. ST-801 245-A / Ref. 183 308 1 Circuit Breaker CB1 2 Circuit Breaker CB2 CB1 protects 1 10 volt ac portion of Remote 14 receptacle (see Section 3-6) from overload. CB2 protects 24 volt ac portion of Remote 14 receptacle from overload.
OM-193 084 Page 25 SECTION 6 – ELECTRICAL DIAGRAM 197 552 Figure 6-1. Circuit Diagram For Welding Power Source.
OM-193 084 Page 26 SECTION 7 – P ARTS LIST 802 500 – B Figure 7-1. Main Assembly.
OM-193 084 Page 27 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly Quantity 1 +175 148 WRAPPER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-193 084 Page 28 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly (Continued) Quantity 46 207 467 HEA T SINK, rect 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-193 084 Page 29 Notes.
OM-193 084 Page 30 Notes.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 10/01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor .
PRINTED IN USA 2002 Miller Electric Mfg. Co. 1/02 Miller Elect ric Mfg. Co. An I l li noi s T ool W ork s Company 1635 W est Spencer Street Applet on, W I 5 4914 USA International He adquarters .
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If you have not bought Miller Electric OM-193 084E yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric OM-193 084E - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric OM-193 084E you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric OM-193 084E will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric OM-193 084E, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric OM-193 084E.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric OM-193 084E. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric OM-193 084E along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
