xmt350mpaauto line (lj410832a)

TM-231 242G 2012−01

Eff w/Serial Number LJ410832A

XMT 350 MPaAuto-Line

Arc Welding Power Source

Processes

Description

Multiprocess Welding

Visit our website at

www.MillerWelds.com

File: MULTIPROCESS

™

Effective with Serial No. LJ410832A

�

INFORMATION ON OLDER UNITS� This manual includes operating information for current units. To obtain specific operating information for older models, download the applica-

ble Owner’s Manual from www.MillerWelds.com

� Effective with LJ410832A, Synergic Pulsed MIG capability added).

� Effective with MA100311A, Optional Low Open Circuit Voltage welding modes added (VRD).

� Effective with MA370426A, Remote Process Select capability added.

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2. Servicing Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3. California Proposition 65 Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Features And Benefits 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3. Arc Controls 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4. Duty Cycle And Overheating 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Serial Number And Rating Label Location 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2. Dimensions And Weight 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3. Selecting a Location 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4. Weld Output Receptacles And Selecting Cable Sizes 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5. Remote 14 Receptacle Information 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6. Optional 115 Volts AC Duplex Receptacle And Supplementary Protectors 7. . . . . . . . . . . . . . . . . . . . .3-7. Optional Gas Valve Operation And Shielding Gas Connection 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8. Electrical Service Guide 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9. Connecting 1-Phase Input Power 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10. Connecting 3-Phase Input Power 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − GENERAL OPERATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Front Panel 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Mode Switch Settings 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. Configuration Option Menu 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − GTAW OPERATION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Typical Connection For GTAW Process 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Scratch Start TIG Welding Mode - GTAW Process 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3. Lift-Arc TIG Welding Mode - GTAW Process 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4. TIG Welding Mode - GTAW Process 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − GMAW/GMAW-P/FCAW OPERATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Typical Connection For Remote Control Feeder GMAW/GMAW-P/FCAW Process 20. . . . . . . . . . . . . .6-2. MIG Welding Mode - GMAW/FCAW Process 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3. MIG - Wire and Gas Selection Table 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4. Pulsed MIG Welding Mode - GMAW-P Process 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5. Pulsed MIG - Wire and Gas Selection Table 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6. Remote Process Select 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7. Typical Connection For Voltage-Sensing Feeder GMAW/GMAW-P/FCAW Process 26. . . . . . . . . . . . . .6-8. V-Sense Feeder Welding Mode - GMAW/FCAW Process 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9. V-Sense Feeder Welding Mode - GMAW-P Process 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − SMAW/CAC-A OPERATION 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1. Typical Connection For SMAW And CAC-A Process 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2. CC Welding Mode - SMAW/CAC-A Process 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3. Stick Welding Mode - SMAW/CAC-A Process 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4. Optional Low Open Circuit Voltage (OCV) Welding Modes 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − THEORY OF OPERATION 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 9 − TROUBLESHOOTING 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Checking Unit Before Applying Power 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2. Measuring Input Capacitor Voltage 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 9 − TROUBLESHOOTING (Continued) 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3. Input Pre-Regulator Module (MOD1) 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4. Input Pre-Regulator Module (MOD1) Test Point Values 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5. Inverter Module (MOD2) 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6. Inverter Module (MOD2) Test Point Values 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-7. Power Interconnect Board PC2 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8. Power Interconnect Board PC2 Test Point Values 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9. Control Board PC1 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10. Control Board PC1 − Test Point Values 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11. Power Switch (S1) 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-12. Output Diodes D1, D2 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13. Output Diodes D1, D2 Test Point Values 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14. Stick Boost Rectifier (SR1) 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15. Stick Boost Rectifier (SR1) Test Point Values 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-16. Troubleshooting Table 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17. Help Displays 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18. Troubleshooting Circuit Diagram 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-19. Control Board PC1 Testing Information (Use with Section 9-20) 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-20. Control Board PC1 Test Point Values 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-21. Control Board PC1 − Power Off Checks (Prior To MA070470A) 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-22. Control Board PC1 − Power Off Checks (Prior To MA070470A) 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-23. Control Board PC1 - Power Off Checks (Effective With MA070470A) 58. . . . . . . . . . . . . . . . . . . . . . . . .9-24. Control Board PC1 − Power Off Checks (Effective With MA070470A) 59. . . . . . . . . . . . . . . . . . . . . . . . .9-25. Power Interconnect Board PC2 Testing Information (Use with Section 9-26) 60. . . . . . . . . . . . . . . . . . . .

9-26. Power Interconnect Board PC2 Test Point Values 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-27. Power Interconnect Board (PC2) - Power Off Checks (Prior To MB510232A) 64. . . . . . . . . . . . . . . . . . .9-28. Power Interconnect Board (PC2) - Power Off Checks (Prior To MB510232A) 65. . . . . . . . . . . . . . . . . . .9-29. Power Interconnect Board (PC2) - Power Off Checks (Effective With MB510232A) 66. . . . . . . . . . . . . .9-30. Power Interconnect Board (PC2) - Power Off Checks (Effective With MB510232A) 67. . . . . . . . . . . . . .

9-31. Front Panel/Display Board PC3 Testing Information (Use with Section 9-32) 68. . . . . . . . . . . . . . . . . . . .9-32. Front Panel/Display Board PC3 Test Point Values 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-33. Checking Unit Output After Servicing 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-34. Enabling Low Open Circuit Voltage Welding Modes (Optional) Effective W/MA100311A 71. . . . . . . . . .

SECTION 10 − MAINTENANCE 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1. Routine Maintenance 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2. Blowing Out Inside Of Unit 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3. Removing Fan Motor 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − ELECTRICAL DIAGRAMS 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 12 − PARTS LIST FOR LJ410832A AND FOLLOWING 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-231 242 Page 1XMT 350 MPa

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICINGProtect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol UsageOM-231 242-L, safety_stm 2011−10

DANGER! − Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.

Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards 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! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-bols and related instructions below for necessary actions to avoid thehazards.

1-2. Servicing Hazards

The symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard.

Only qualified persons should test, maintain, and repair thisunit.

During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

� Do not touch live electrical parts.� Turn Off welding power source and wire feeder

and disconnect and lockout input power usingline disconnect switch, circuit breakers, or by removing plug from re-ceptacle, or stop engine before servicing unless the procedure spe-cifically requires an energized unit.

� Insulate yourself from ground by standing or working on dry insulat-ing mats big enough to prevent contact with the ground.

� Do not leave live unit unattended.

� If this procedure requires an energized unit, have only personnelfamiliar with and following standard safety practices do the job.

� When testing a live unit, use the one-hand method. Do not put bothhands inside unit. Keep one hand free.

� Disconnect input power conductors from deenergized supply lineBEFORE moving a welding power source.

SIGNIFICANT DC VOLTAGE exists in inverter weld-ing power sources AFTER removal of input power.

� Turn Off inverter, disconnect input power, and discharge inputcapacitors according to instructions in Troubleshooting Section be-fore touching any parts.

STATIC (ESD) can damage PC boards.

� Put on grounded wrist strap BEFORE handlingboards or parts.

� Use proper static-proof bags and boxes tostore, move, or ship PC boards.

FIRE OR EXPLOSION hazard.

� Do not place unit on, over, or near combustiblesurfaces.

� Do not service unit near flammables.

FLYING METAL or DIRT can injure eyes.

� Wear safety glasses with side shields or faceshield during servicing.

� Be careful not to short metal tools, parts, orwires together during testing and servicing.

HOT PARTS can burn.

� Do not touch hot parts bare handed.� Allow cooling period before working on

equipment.� To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves andclothing to prevent burns.

EXPLODING PARTS can injure.

� Failed parts can explode or cause other parts toexplode when power is applied to inverters.

� Always wear a face shield and long sleeveswhen servicing inverters.

SHOCK HAZARD from testing.

� Turn Off welding power source and wire feederor stop engine before making or changing me-ter lead connections.

� Use at least one meter lead that has a self-retaining spring clip such as an alligator clip.

� Read instructions for test equipment.

FALLING EQUIPMENT can injure.

� Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

� Use equipment of adequate capacity to lift andsupport unit.

� If using lift forks to move unit, be sure forks are long enough toextend beyond opposite side of unit.

� Follow the guidelines in the Applications Manual for the RevisedNIOSH Lifting Equation (Publication No. 94−110) when manu-ally lifting heavy parts or equipment.

TM-231 242 Page 2 XMT 350 MPa

MOVING PARTS can injure.

� Keep away from moving parts such as fans.� Keep away from pinch points such as drive

rolls.� Have only qualified persons remove doors,

panels, covers, or guards for maintenance andtroubleshooting as necessary.

� Keep hands, hair, loose clothing, and toolsaway from moving parts.

� Reinstall doors, panels, covers, or guardswhen maintenance is finished and before re-connecting input power.

ELECTRIC AND MAGNETIC FIELDS (EMF)can affect Implanted Medical Devices.

� Wearers of Pacemakers and other ImplantedMedical Devices should keep away from serv-icing areas until consulting their doctor and thedevice manufacturer.

OVERUSE can cause OVERHEATING.

� Allow cooling period; follow rated duty cycle.� Reduce current or reduce duty cycle before

starting to weld again.� Do not block or filter airflow to unit.

H.F. RADIATION can cause interference.

� High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

� Have only qualified persons familiar withelectronic equipment install, test, and serviceH.F. producing units.

� The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

� If notified by the FCC about interference, stop using theequipment at once.

� Have the installation regularly checked and maintained.

� Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

READ INSTRUCTIONS.

� Use Testing Booklet (Part No. 150 853) whenservicing this unit.

� Consult the Owner’s Manual for welding safetyprecautions.

� Use only genuine replacement parts from the manufacturer.� Read and follow all labels and the Technical Manual carefully be-

fore installing, operating, or servicing unit. Read the safety in-formation at the beginning of the manual and in each section.

1-3. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of California tocause birth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code Section 25249.5 et seq.)

This product contains chemicals, including lead, known tothe state of California to cause cancer, birth defects, or otherreproductive harm. Wash hands after use.

1-4. EMF Information

Electric current flowing through any conductor causes localized electricand magnetic fields (EMF). Welding current creates an EMF fieldaround the welding circuit and welding equipment. EMF fields may inter-fere with some medical implants, e.g. pacemakers. Protectivemeasures for persons wearing medical implants have to be taken. Forexample, restrict access for passers−by or conduct individual risk as-sessment for welders. All welders should use the following proceduresin order to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using acable cover.

2. Do not place your body between welding cables. Arrange cablesto one side and away from the operator.

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

4. Keep head and trunk as far away from the equipment in thewelding circuit as possible.

5. Connect work clamp to workpiece as close to the weld aspossible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wirefeeder.

About Implanted Medical Devices:Implanted Medical Device wearers should consult their doctor and thedevice manufacturer before performing or going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heating operations.If cleared by your doctor, then following the above procedures is recom-mended.


SECTION 2 − INTRODUCTION

2-1. Specifications

InputPower Rated Output

Voltage Range in CV Mode

AmperageRange inCC Mode

Max.Open-CircuitVoltage

RMS Amps Input at Rated Load Output,60 Hz 3-Phase at NEMA Load Voltages

and Class I Rating

KVA KW208 V 230 V 400 V 460 V 575 V

3-Phase 350 A at 34VDC, 60%Duty Cycle

10−38 V 5−425 A 75 VDC 40.4 36.1 20.6 17.8 14.1 14.2 13.6

1-Phase 300 A at 32VDC, 60%

Duty Cycle*

60.8 54.6 29.7 25.4 19.9 11.7 11.2

*See Section 2-4 for Duty Cycle Rating.

2-2. Features And Benefits

Auto-Line� Power Management Technology is circuitry that automatically adapts the power source to the primaryvoltage being applied (see Sections 3-9 and 3-10).

LVC� Line Voltage Compensation is circuitry that keeps the power source output constant regardless of input pow-er fluctuation.

Wind Tunnel Technology� circulates air over components that require cooling, not over electronic circuitry, whichreduces contaminants and improves reliability in harsh welding environments.

Fan-On-Demand� cooling system operates only when needed, reducing noise, energy use and the amount of con-taminants pulled through the machine.

Thermal Overload Protection automatically shuts down the unit, only when necessary to prevent damage to internalcomponents if the duty cycle is exceeded or air flow and cooling are restricted (see Section 2-4).

Auto Remote Sense enables the unit to automatically sense the connection of a remote control. Operation of theremote control is dependent on the Mode Switch Setting (see Section 4-2).

Lift-Arc� TIG starts provide a contamination free weld without the use of high frequency in the Lift-Arc TIG WeldingMode (see Section 5-3).

Synergic Pulsed MIG Operation allows single knob control of the arc. As wirefeed speed is increased or decreased,the pulse parameters increase or decrease matching the power output to the wire speed (see Section 4-3).

2-3. Arc Controls

DIG control allows the arc characteristics, soft versus stiff, to be changed for specific applications and electrodes inCC and Stick Welding Modes (see Sections 7-2 and 7-3).

Programmable Hot Start allows the start amperage and time to be changed for CC and Stick Welding Modes (seeSections 7-2 and 7-3).

Inductance influences the arc stiffness, bead width and appearance, and puddle fluidity in MIG and V-Sense FeederWelding Modes (see Sections 6-2 and 6-8).

SharpArc� optimizes the size and shape of the arc cone, bead width and appearance, and puddle fluidity in PulsedMIG Welding Mode (see Section 6-4).


6 Minutes Welding 4 Minutes Resting

2-4. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.

If unit overheats, output stops, a Helpmessage is displayed and cooling fanruns. Wait fifteen minutes for unit tocool. Reduce amperage or voltage, orduty cycle before welding.

� Single Phase Operation: Theunit is supplied with a 8 AWGpower cord. The rated outputwith 8 AWG is 300 amps, 32volts at 40% duty cycle. Toachieve 60% duty cycle changecord to 6 AWG.

NOTICE − Exceeding duty cycle candamage unit and void warranty.

60% Duty Cycle

Overheating0

15

A or V

ORReduce Duty CycleMinutes

Ref. 216 568-A


SECTION 3 − INSTALLATION

3-1. Serial Number And Rating Label LocationThe serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/orrated output. For future reference, write serial number in space provided on back cover of this manual.

3-2. Dimensions And Weight

Hole Layout Dimensions

24 in.(610 mm)

17 in.(432 mm)

12-1/2 in.(318 mm)

804 801-A

A

DC

B

E

GFA 11-3/4 in. (298 mm)

B 1-11/16 in. (42 mm)

C 15-3/4 in. (400 mm)

D 19-3/32 in. (485 mm)

E 8-11/16 in. (221 mm)

F 1-17/32 in. (39 mm)

G 1/4-20 UNC -2B thread

Weight

80 lb (36.3 kg)93.5 lb (42.4 kg)

w/optional 115 VAC

! Do not move or operate unitwhere it could tip.

3-3. Selecting a Location

XMT Location 1

1 Lifting Handles

Use handles to lift unit.

2 Hand Cart

Use cart or similar device to moveunit.

3 Line Disconnect Device

Locate unit near correct inputpower supply.

! Special installation may berequired where gasoline orvolatile liquids are present −see NEC Article 511 or CECSection 20.

Movement 1

2

Location 3

18 in.(460 mm)

18 in.(460 mm)

1


3-4. Weld Output Receptacles And Selecting Cable SizesNOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cablesize.

! Turn off power be-fore connecting toweld output termi-nals.

! Do not use worn,damaged, under-sized, or poorlyspliced cables.

Weld OutputTerminals

Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***

100 ft (30 m) or Less 150 ft(45 m)

200 ft(60 m)

250 ft(70 m)

300 ft(90 m)

350 ft(105 m)

400 ft(120 m)

WeldingAmperes

10 − 60%DutyCycle

AWG (mm2)

60 − 100%DutyCycle

AWG (mm2)

10 − 100% Duty Cycle

AWG (mm2)

+

−Output Receptacles

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)2x2/0(2x70)

2x2/0(2x70)

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (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)

500 2/0 (70) 3/0 (95) 4/0 (120)2x2/0(2x70)

2x3/0(2x95)

2x4/0(2x120)

3x3/0(3x95)

3x3/0(3x95)

600 3/0 (95) 4/0 (120)2x2/0(2x70)

2x3/0(2x95)

2x4/0(2x120)

3x3/0(3x95)

3x4/0(3x120)

3x4/0(3x120)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**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.( ) = mm2 for metric use

***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Ref. S-0007-J 2011−07


3-5. Remote 14 Receptacle Information

A JB K I

C L N H

D M GE F

Socket* Socket Information

24 VOLTS ACA 24 volts AC. Protected by supplementary protect-

or CB2.

B Contact closure to A completes 24 volts ACcontactor control circuit.

115 VOLTS ACI 115 volts AC. Protected by supplementary pro-

tector CB1.

J Contact closure to I completes 115 volts ACcontactor control circuit.

REMOTEOUTPUT

CONTROL

C Output to remote control; 0 to +10 volts DC, +10volts DC in MIG mode.

D Remote control circuit common.

E 0 to +10 volts DC input command signal fromremote control.

L Wirefeed speed command, 0 to +10 volts DC out-put signal from wire feeder.

M CC/CV Select; 0 to +10 volts DC.

N Wirefeed speed common.

A/VAMPERAGEVOLTAGE

F Current feedback; +1 volt DC per 100 amperes.

H Voltage feedback; +1 volt DC per 10 output recep-tacle volts.

GNDG Circuit common for 24 and 115 volts AC circuits.

K Chassis common.

*The remaining sockets are not used.

803 691-C

1 115 V 10 Amp AC Receptacle

Power is shared between duplexreceptacle and Remote 14 recep-tacle (see Section 3-5).

2 Supplementary Protector CB1

3 Supplementary Protector CB2

CB1 protects duplex receptacleand 115 volts AC portion of Remote14 receptacle from overload.

CB2 protects 24 volts AC portion ofRemote 14 receptacle fromoverload.

Press button to reset supplement-ary protector.

2 3

1

3-6. Optional 115 Volts AC Duplex Receptacle And Supplementary Protectors


3-7. Optional Gas Valve Operation And Shielding Gas Connection

Ref. 803 705-A / Ref. 803 691-C

Obtain gas cylinder and chain torunning gear, wall, or other station-ary support so cylinder cannot falland break off valve.

1 Cylinder

2 Regulator/Flowmeter

Install so face is vertical.

3 Gas Hose Connection

Fitting has 5/8-18 right-handthreads. Obtain and install gashose.

4 Gas In Fitting

5 Gas Out Fitting

The Gas In and Gas Out fittingshave 5/8-18 right-hand threads.Obtain proper size, type, and lengthhose and make connections as fol-lows:

Connect hose from shielding gassupply regulator/flowmeter to GasIn fitting.

Connect hose coupler to torch.Connect one end of gas hose tohose coupler. Connect remainingend of gas hose to Gas Out fitting.

Operation

The gas solenoid controls gas flowduring the TIG process as follows:

Remote TIG

Gas flow starts with remote contac-tor on.

Gas flow stops at end of post−flowif current was detected, or with re-mote contactor off if no current wasdetected.

Lift−Arc TIG

Gas flow starts when tungstentouches work (touch sensed).

Gas flow stops at end of post−flow.

Scratch Start TIG

Gas flow starts when current is de-tected.

Gas flow stops at end of post−flow.

Post−flow time is factory set to 5seconds per 100 amps of weld cur-rent. The minimum post−flow timeis 5 seconds. The maximum post−flow is 20 seconds (post flow set-tings are not adjustable by the enduser).

4

3

1

2

GAS IN

GAS OUT

5


3-8. Electrical Service Guide

NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage.

NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual inputvoltage is outside this range, output may not be be available.

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-tions are for a dedicated circuit sized for 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 ratingof the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and630.12.

Single-Phase

Input Voltage (V) 208 230 400 460 575

Input Amperes (A) At Rated Output 60.8 54.6 29.7 25.4 19.9

Max Recommended Standard Fuse Rating In Amperes 1

Time-Delay Fuses 2 70 60 35 30 25

Normal Operating Fuses 3 80 80 45 40 30

Min Input Conductor Size In AWG4 8 8 10 12 12

Max Recommended Input Conductor Length In Feet (Meters)72

(22)89

(27)176(54)

140(43)

219(67)

Min Grounding Conductor Size In AWG 4 8 8 10 12 12

Three-Phase

Input Voltage (V) 208 230 400 460 575

Input Amperes (A) At Rated Output 40.4 36.1 20.6 17.8 14.1

Max Recommended Standard Fuse Rating In Amperes 1

Time-Delay Fuses 2 45 40 25 20 15

Normal Operating Fuses 3 60 50 30 25 20

Min Input Conductor Size In AWG4 8 10 12 14 14

Max Recommended Input Conductor Length In Feet (Meters)119(36)

96(29)

175(53)

150(46)

234(71)

Min Grounding Conductor Size In AWG 4 10 10 12 14 14

Reference: 2011 National Electrical Code (NEC) (including article 630)1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.

2 “Time-Delay” fuses are UL class “RK5”. See UL 248.3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and

above).4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cablerequirements.


3-9. Connecting 1-Phase Input Power

! Installation must meet all Na-tional and Local Codes − haveonly qualified persons makethis installation.

! Disconnect and lockout/tag-out input power before con-necting input conductors fromunit.

! Always connect green orgreen/yellow conductor tosupply grounding terminalfirst, and never to a line termi-nal.

� The Auto-Line circuitry in this unitautomatically adapts the powersource to the primary voltage be-ing applied. Check input voltageavailable at site. This unit can beconnected to any input power be-tween 208 and 575 VAC withoutremoving cover to relink the pow-er source.

See rating label on unit and check in-put voltage available at site.

1 Black And White InputConductor (L1 And L2)

2 Red Input Conductor

3 Green Or Green/YellowGrounding Conductor

4 Insulation Sleeving

5 Electrical Tape

Insulate and isolate red conductor asshown.

6 Input Power Cord.

7 Disconnect Device (switchshown in the OFF position)

8 Disconnect Device GroundingTerminal

9 Disconnect Device LineTerminals

Connect green or green/yellowgrounding conductor to disconnectdevice grounding terminal first.

Connect input conductors L1 and L2to disconnect device line terminals.

10 Overcurrent Protection

Select type and size of overcurrentprotection using Section 3-8 (fuseddisconnect switch shown).

Close and secure door on disconnectdevice. Remove lockout/tagout de-vice, and place switch in the On posi-tion.

7

6

L1

L2

1

=GND/PEEarth

Ground

3

1

8

9

10

Tools Needed:

1

6

54

2

3

input1 2011−03 − 803 766-C


3-10. Connecting 3-Phase Input Power

! Installation must meet all Nationaland Local Codes − have only quali-fied persons make this installation.

! Disconnect and lockout/tagout in-put power before connecting inputconductors from unit.

! Always connect green or green/yellow conductor to supplygrounding terminal first, and neverto a line terminal.

� The Auto-Line circuitry in this unit au-tomatically adapts the power sourceto the primary voltage being applied.Check input voltage available at site.This unit can be connected to any in-put power between 208 and 575 VACwithout removing cover to relink thepower source.

See rating label on unit and check inputvoltage available at site.

For Three-Phase Operation

1 Input Power Cord.

2 Disconnect Device (switch shown inthe OFF position)

3 Green Or Green/Yellow GroundingConductor

4 Disconnect Device GroundingTerminal

5 Input Conductors (L1, L2 And L3)

6 Disconnect Device Line Terminals

Connect green or green/yellow groundingconductor to disconnect device groundingterminal first.

Connect input conductors L1, L2, and L3to disconnect device line terminals.

7 Overcurrent Protection

Select type and size of overcurrent protec-tion using Section 3-8 (fused disconnectswitch shown).

Close and secure door on disconnectdevice. Remove lockout/tagout device,and place switch in the On position.

= GND/PE Earth Ground

L1

2

1

L2

L3

3

3

4

5

6

7

Tools Needed:

input1 2011−03 − 803 766-C


SECTION 4 − GENERAL OPERATION

4-1. Front Panel

� Weld process operation sections de-scribe functionality of the identified items.

1 Remote 14 Receptacle2 Output ON Indicator Light

3 Volts Indicator

4 Left Display

5 Arc Length Indicator

6 Right Display

� The meters display the actual weld outputvalues after arc initiation and remains dis-played for approximately three secondsafter the arc is broken.

7 Amps Indicator8 Setup Indicator9 Adjust Control10 Wire Type Indicator11 Arc Control Indicator

12 Remote PC Interface

13 Setup Button

14 Gas Type Indicator

15 Mode Switch

16 Power Switch

17 Weld Output Terminal (−)

18 Optional Gas Valve Knockout

19 Weld Output Terminal (+)

804 772-A / 226 611-A

16

4 6 9

151

13

2

12

19

18

17

3 5 7 8

14

1110


4-2. Mode Switch Settings

Switch Position Process Output Control Panel Adjust Remote Adjust

Scratch Start TIG GTAW Electrode Hot Amps % Panel Amps*

Lift-Arc TIG GTAW Electrode Hot Amps % Panel Amps*

TIG GTAW Remote 14 Amps % Panel Amps

MIG GMAW Remote 14 Volts Volts

Pulsed MIG GMAW-P Remote 14 Arc Length (0−100)* Arc Length (0−100)*

CCSMAW

CAC-ARemote 14 Amps % Panel Amps

StickSMAW

CAC-AElectrode Hot Amps % Panel Amps*

V-Sense Feeder GMAW* Electrode Hot Volts Volts

*See Configuration Option Menu (see Section 4-3) For adjustment alternatives.

Notes


4-3. Configuration Option Menu

1 Mode Switch

2 Remote 14 Receptacle

3 Left Display

4 Right Display

5 Adjustment Control

6 Remote PC Interface

7 Setup Button

Setup

The Configuration Option Menu provides ameans to customize some machine featuresfor desired operation.

To enter the Configuration Option Menu, holdthe Setup Button down during power up whilethe unit is displaying 8888 on the Left and

Right Displays. SET−UP will be displayedmomentarily.Configuration options are displayed in the LeftDisplay. Settings are displayed in the RightDisplay. Settings can be changed by turningthe Adjust Control. If a setting does notchange when the Adjust Control is turned, theoption is not configurable. Pressing the SetupButton moves to the next configuration option.

226 611-A

3 4 5

1

6

2

SET -UP

7


4-3 Configuration Option Menu (Continued)

V-Sense Feeder Weld Process

This option enables MIG (V.SEN MIG) or Pulsed MIG(V.SEN PULS) when the Mode Switch is in the VSENSEFEEDER position. See Section 6-2 for MIG operation or Sec-tion 6-4 for Pulsed MIG operation.

Pulsed MIG Manual/Auto Control

This option sets the PULSED MIG control as manual (PULSMAN) or Auto (PULS AUTO) operation. When set to manualoperation, the arc length setting on power source and wirespeed setting on wirefeeder need to be adjusted indepen-dently to achieve the desired arc length. When set to Auto op-eration, once arc length is determined it is not necessary tochange the arc length value with changes in wirefeed speed.

The XMT 350 MPa and synergic feeders allow single knobcontrol of the arc. As wirefeed speed is increased or de-creased, the pulse parameters increase or decrease match-ing the power output to the wire speed.

� Auto Operation will only work with synergic wirefeeders.All other wirefeeders will only operate as manual control.Even when Auto is displayed, operation will be manualwhen any other feeder is connected. See product literat-ure for a list of compatible synergic feeders.

Pulsed MIG Adjustment

This option allows adjusting the Pulsed MIG process in unitsof Arc Length (PULS ARC.L) or preset voltage (PULSVOLT).

Wire Feed Speed And Wire Diameter Units

WFS IPM:WFS is displayed in inches per minuteDiameter is displayed in inches

WFS MPM:WFS is displayed in meters per minuteDiameter is displayed in millimeters

Voltage Reducing Device (VRD) Mode

This option enables (ON) or disables (OFF) low open circuitvoltage (OCV) operation in Stick and Scratch Start TIGmodes. See Section 7-4 for Low OCV Operation. When en-abled, VRD ON is momentarily displayed after the power-onfront panel LED test.

� If VRD -ON is displayed with a dash preceding ON, LowOCV Operation is enabled by hardware configurationand cannot be disabled in this menu.

Panel and Remote Adjustment

When the Mode Switch is set to SCRATCH START TIG,LIFT−ARC TIG, or STICK, the remote command behavior isconfigurable. SCRATCH START TIG and LIFT−ARC TIGdefault to panel and remote (PANL RMT) amperage adjust-ment but can be configured for panel only (PANL ONLY) ad-justment. The default amperage adjustment for STICK ispanel only (PANL ONLY) but can also be configured for paneland remote (PANL RMT) adjustment. All other Mode Switchpositions are non−configurable and allow both panel and re-mote (PANL −RMT) adjustment.

� Panel adjustment is made using the Adjust Control onthe front panel. Remote adjustment is made using a re-mote control device connected to the Remote 14 Recep-tacle.

PULS ARC.L

PANL RMT

PULS AUTO

V.SEN MIG

VRD OFF

WFS IPM


4-3 Configuration Option Menu (Continued)

Revision Information

This option identifies the unit’s weld library (INFOLIB) and firmware revision (INFO REV).

Press the Setup Button while the unit is display-ing INFO LIB to identify the unit’s weld library.

Press the Setup Button while the unit is display-ing INFO REV to identify the unit’s firmware revi-sion.

Pressing the Setup Button while the unit is dis-playing INFO NO will move to the next configura-tion option.

Exit Configuration Option Menu

Press the Setup Button while the unit is display-ing EXIT NO to return to the first configuration op-tion. Press the Setup Button while the unit is dis-playing EXIT YES to exit the Configuration Op-tion Menu.

� The Configuration Option Menu can be ex-ited at any time by turning the unit off. Onlyif the unit is turned off after EXIT NO is dis-played will configuration option changes besaved.

INFO NO

EXIT NO

SECTION 5 − GTAW OPERATION

5-1. Typical Connection For GTAW Process

804 841-B

! Turn off power before mak-ing connections.

1 Foot Control

2 Gas Out Connection(Optional)

3 Positive (+) Weld OutputTerminal


Connect desired remote control toRemote 14 receptacle if required.

5 Gas In Connection (Optional)

6 Gas Cylinder

7 Negative (−) Weld OutputTerminal

8 TIG Torch

9 Workpiece

4

7

5

3

2

1

8

6

9


5-2. Scratch Start TIG Welding Mode - GTAW Process

! Weld terminals are energized at alltimes in Scratch Start TIG weldingmode.

1 Mode Switch

2 Volts Indicator

3 Left Display

4 Right Display

5 Amps Indicator

6 Adjust Control

Setup

For typical system connections refer toSection 5-1.

Rotate Mode Switch to SCRATCH STARTTIG position as shown.

The open circuit voltage is shown in the LeftDisplay with the Volts Indicator lit. Presetamperage is shown in the Right Displaywith the Amps Indicator lit.

Operation

The Adjust Control is used to set desiredpreset amperage.

� If a remote control is used for amper-age adjustment, the adjustment willfunction as a percentage of the presetamperage.

� For best results, gently scratch thetungsten electrode to the work to initi-ate an arc. To minimize arc flare at theend of the weld, pull back the electrodequickly to extinguish the arc.

226 611-A

3

1

87 2. 0 5

4 5 62


5-3. Lift-Arc TIG Welding Mode - GTAW Process

! Weld terminals are energized at alltimes in Lift Arc TIG welding mode.

1 Mode Switch

2 Volts Indicator

3 Left Display

4 Right Display

5 Amps Indicator

6 Adjust Control

7 Workpiece

8 Tungsten Electrode

Setup


Rotate Mode Switch to LIFT-ARC TIG posi-tion as shown.

The open-circuit voltage is shown in theLeft Display with the Volts Indicator lit. Pre-set amperage is shown in the Right Displaywith the Amps Indicator lit.

Normal open-circuit voltage is not presentbefore the electrode touches the work-piece, instead a low sensing voltage ispresent. The sensing voltage allows theelectrode to touch the workpiece withoutoverheating, sticking, or getting contami-nated.

Operation

The Adjust Control is used to set desiredpreset amperage.

� If a remote control is used for amper-age adjustment, the adjustment willfunction as a percentage of the presetamperage.

� For best results, firmly touch the tung-sten electrode to the workpiece at theweld start point. Hold electrode toworkpiece for 1-2 seconds, and liftelectrode. An arc will form when theelectrode is lifted. To minimize arc flareat the end of the weld, pull back theelectrode quickly to extinguish the arc.

226 611-A1

6

8

1 − 2Seconds“Touch”

1 3. 5 5

Do NOT Strike Like A Match!

87

3 4 52


5-4. TIG Welding Mode - GTAW Process

! Weld terminals are energizedthrough the remote control in TIGwelding mode.

1 Mode Switch

2 Left Display

3 Right Display

4 Amps Indicator

5 Adjust Control

SetupFor typical system connections refer toSection 5-1.Rotate Mode Switch to TIG position asshown.The preset amperage is shown in the RightDisplay with the Amps Indicator lit.

OperationThe Adjust Control is used to set desiredpreset amperage.A remote control is required to turn on theweld output.

� If the remote control has an amperageadjustment, the adjustment will func-tion as a percentage of the preset am-perage.

� For best results, gently scratch thetungsten electrode to the work to initi-ate an arc. To minimize arc flare at theend of the weld, pull back the electrodequickly to extinguish the arc.

1

5

226 611-A

85

2 3 4

8 5


SECTION 6 − GMAW/GMAW-P/FCAW OPERATION

6-1. Typical Connection For Remote Control Feeder GMAW/GMAW-P/FCAW Process

804 938-A

! Turn off power before making connections.

1 Remote 14-Receptacle

2 Positive (+) Weld Output Terminal

3 Negative (−) Weld Output Terminal

4 Ground Cable to Workpiece

5 Workpiece

6 Gun

7 Wire Feeder

8 Gas Hose

9 Gas Cylinder

Use of shielding gas is dependant on WireType.

� The connection diagram illustratesDCEP (reverse polarity) suitable for allwires except self-shielded FCAW. Themajority of self-shielded FCAW wiresrequire DCEN (straight polarity).

2

3

4

5

1

6

7

8

9


6-2. MIG Welding Mode - GMAW/FCAW Process

! Weld terminals are energizedthrough the remote control in MIGwelding mode.

1 Mode Switch

2 Volts Indicator

3 Left Display

4 Right Display

5 Adjust Control

6 Wire Type Indicator

7 Arc Control Indicator

8 Setup Button


Setup


Rotate Mode Switch to MIG position asshown.

The preset voltage is shown in the Left Dis-play with the Volts Indicator lit.

Operation

While the Volts Indicator is lit under the LeftDisplay, the Adjust Control is used to setdesired preset voltage.

� The preset voltage can be adjusted re-motely at the wire feeder if the feederhas a voltage control. This voltage con-trol will override the Adjust Control ofpreset voltage on the welding powersource.

Pressing the Setup Button allows adjust-ment of Arc Control, Wire Type, Gas Typeand preset voltage.

� For best results, select the appropriateWire and Gas Type to match the actualwire and gas being used. Refer to theMIG − Wire and Gas Selection Tablefor available wires and gases (seeSection 6-3).

Selecting a Wire and Gas

Press the Setup Button repeatedly until theWire Type indicator is lit. The active WireType will appear in the Left and Right Dis-play.

Rotate Adjust Control to select desiredwire.

Press the Setup Button again so the GasType indicator is lit. The active Gas Typewill appear in the Left and Right Display.

Rotate Adjust Control to select desired gas.

Press the Setup Button to confirm theselection. The unit will acknowledge achange of wire and gas information by dis-playing PROG LOAD momentarily.

Arc Control (Inductance)

Press the Setup Button repeatedly until theArc Control indicator is lit. INDU appears onthe Left Display, and the corresponding in-ductance setting appears on the Right Dis-play.

Rotate Adjust Control to select desired in-ductance setting from 0 to 100. Use lowerinductance settings to stiffen the arc and re-duce puddle fluidity. Use higher inductancesettings to soften the arc and increasepuddle fluidity.

Refer to the MIG − Wire and Gas SelectionTable (see Section 6-3) for suggested in-ductance setting for the specific wire andgas being used.

Press the Setup Button to return to adjust-ment of preset voltage.

� Each Wire and Gas Type combinationhas independent preset voltage and in-ductance settings. These settings arepreserved when the unit is turned off.

1

543

226 611-A

2 5. 0

2

6

7

8

9


6-3. MIG - Wire and Gas Selection Table

WIRE TYPES** GAS TYPES DEFAULT INDUCTANCE

Steel

.035 (0.9) STL

.045 (1.2) STL

.052 (1.4) STL

ARGN CO2 (ARGON / CARBON DIOXIDE)ARGN OXY (ARGON / OXYGEN) 30

.035 (0.9) STL

.045 (1.2) STL CO2 (CARBON DIOXIDE) 10

Flux Core

.035 (0.9) FCAW

.045 (1.2) FCAW

.052 (1.4) FCAW1/16 (1.6) FCAW

ARGN CO2 (ARGON / CARBON DIOXIDE) *CO2 (CARBON DIOXIDE) 30 *

Metal Core.045 (1.2) MCOR.052 (1.4) MCOR1/16 (1.6) MCOR

ARGN CO2 (ARGON / CARBON DIOXIDE) 30

Stainless Steel.035 (0.9) SSTL.045 (1.2) SSTL

TRI MIX (TRI-GAS MIXTURE)ARGN OXY (ARGON / OXYGEN) 70

Aluminum

.035 (0.9) AL4X (4000 Series)

.040 (1.0) AL4X (4000 Series)3/64 (1.2) AL4X (4000 Series)1/16 (1.6) AL4X (4000 Series)

.035 (0.9) AL5X (5000 Series)


ARGN (ARGON) 10

*For self-shielded FCAW wires use the ARGN CO2 gas selection and set inductance to less than 10.

**Wire diameter in inches (mm). Refer to section 4-3 to change displayed units.

Notes


6-4. Pulsed MIG Welding Mode - GMAW-P Process

! Weld terminals are energizedthrough the remote control inPulsed MIG welding mode.

1 Mode Switch

2 Volts Indicator

3 Left Display

4 Right Display

5 Arc Length Indicator6 Adjust Control



9 Setup Button


Setup


Rotate Mode Switch to PULSED MIG posi-tion as shown.

The arc length setting is shown in the LeftDisplay with the Arc Length Indicator lit.

Operation

While the Arc Length Indicator is lit underthe Left Display, the Adjust Control is usedto set desired arc length setting.

� The arc length can be adjusted remote-ly at the wire feeder if the feeder has avoltage control. This voltage controlwill override the Adjust Control on thewelding power source.

Pressing the Setup Button allows adjust-ment of Arc Control, Wire Type, Gas Typeand Arc Length.

� For best results, select the appropriateWire and Gas Type to match the actualwire and gas being used. Refer to

Pulsed MIG − Wire and Gas SelectionTable for available wires and gases(see Section 6-5).






Press the Setup Button again to confirm theselection. The unit will acknowledge achange of wire and gas information by dis-playing PROG LOAD momentarily.

Arc Control (SharpArc)

Press the Setup Button repeatedly until theArc Control indicator is lit. SHRP appearson the Left Display, and the correspondingSharpArc setting appears on the Right Dis-play.

Rotate Adjust Control to select desiredSharpArc setting from 0 to 50, default is 25.Adjusting the SharpArc setting changes thewelding arc cone. Lower settings widen thearc cone, increases puddle fluidity and flat-tens the weld bead appearance.

Higher settings narrow the arc cone, re-duces puddle fluidity and crowns the weldbead appearance.

� Each Wire and Gas Type combinationhas independent Arc Length and Shar-pArc settings. These settings are pre-served when the unit is turned off.

Arc Length - Pulsed MIG Manual Control(see Section 4-3)

Arc length corresponds to the level of ener-gy needed to burn off the welding electrode.As wire feed speed increases, a higher arclength setting is required to burn off theadditional wire. The arc length setting ap-pears in the Left Display when the ArcLength Indicator is lit. Arc length can be ad-justed from 0 to 100.

After the welding output terminals are ener-gized, but prior to arc initiation, the unit dis-plays the letter “R” and a reference wirespeed (IPM) on the Right Display. The ref-erence wire speed can be used as a start-ing point for the wire speed setting at thefeeder. The wire speed and arc length set-ting can then be further adjusted to achievethe desired arc length.

The Configuration Option Menu (see Sec-tion 4-1) can be used to change the arclength setting (0 to 100) to average arc volt-age. Average arc voltage can be used as analternative method to set the Pulsed MIGwelding arc with the same parameters(voltage and wire speed) as a conventionalMIG arc. Lower voltage settings corre-spond to tighter arc lengths while highervoltage settings correspond to longer arclengths. If the voltage mode is selected, theaverage voltage preset will be displayed onthe Left Display with the Volts Indicator lit.

Arc Length - Pulsed MIG Auto Control(see Section 4-3)

In Auto operation the arc length setting is0-100. The programs have been developedat 50 arc length setting. Increasing or de-creasing the arc length setting from 50 willchange the arc length. It is not necessary tochange the arc length value when changingwire feed speed settings.

1

643

226 611-A

25.0

2 5

7

8

9

10


6-5. Pulsed MIG - Wire and Gas Selection Table

WIRE TYPES* GAS TYPES

Steel.035 (0.9) STL.045 (1.2) STL

ARGN CO2 (ARGON / CARBON DIOXIDE)ARGN OXY (ARGON / OXYGEN)

Metal Core.045 (1.2) MCOR.052 (1.4) MCOR ARGN CO2 (ARGON / CARBON DIOXIDE)

Stainless Steel.035 (0.9) SSTL.045 (1.2) SSTL

TRI MIX (TRI-GAS MIXTURE)ARGN OXY (ARGON / OXYGEN)

ARGN CO2 (ARGON / CARBON DIOXIDE)

Aluminum

.035 (0.9) AL4X (4000 Series)


ARGN (ARGON)

.035 (0.9) AL5X (5000 Series)


ARGN (ARGON)HE AR25 (HELIUM/ARGON)

Nickel.035 (0.9) NI.045 (1.2) NI

ARGN HE (ARGON / HELIUM)ARGN (ARGON)

Copper Nickel.035 (0.9) CUNI.045 (1.2) CUNI HE ARGN (HELIUM / ARGON)

Silicon Bronze.035 (0.9) SIBR.045 (1.2) SIBR ARGN (ARGON)

*Wire diameter in inches (mm). Refer to section 4-3 to change displayed units.

� Other normal gas mixtures can be used by adjusting arc length and sharp arc. Use the program closest to your gas mixture and wire type andsize.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.


6-6. Remote Process Select

This power source can be used with wirefeeders that support Remote Process Se-lect. This feature allows the operator toswitch the active welding process betweenMIG and Pulsed MIG at the wire feeder. Todetermine if the welding system is RemoteProcess Select capable, connect the wirefeeder to the power source and review thepower source display variations shown be-low.

� When used with an XMT power source,the Process Select knob must be set toPulsed MIG for Remote Process Selectto be active.

Power Source Display − Wire Feeder withRemote Process Select Not Detected

When the power source Right Display isblank, a wire feeder with Remote ProcessSelect is not detected. Set the active weldprocess at the power source.

Power Source Display − Wire Feeder withRemote Process Select Detected

When the power source Right Display isMIG, a wire feeder with Remote Process Se-lect is detected and set for MIG operation.The active weld process can only bechanged at the wire feeder.

Power Source Display − Wire Feeder withRemote Process Select Detected and Setfor Pulsed MIG

When the power source Right Display isPULS, a Remote Process Select wire feederis detected and is set for Pulsed MIG opera-tion. The active weld process can only bechanged at the wire feeder.

Using a Dual Wire Feeder with RemoteProcess Select

When using a dual wire feeder with RemoteProcess Select, different weld programs forthe left and right side can be selected. Thepower source MIG and Pulsed MIG pro-grams for the left side of wire feeder are se-lected with the left side of the wire feeder act-ive. The power source MIG and Pulsed MIGprograms for the right side are selected withthe right side of the wire feeder active. Whenthe right side of the wire feeder is active, thepower source Right Display will show adecimal point in the lower right hand corneras shown.

Power Source Display − Dual Wire Feed-er with Right Side Active and Set for MIG

Power Source Display − Dual Wire Feed-er with Right Side Active and Set forPulsed MIG

50

25.0 MIG

50 PULS

25.0 MIG.

50 PULS.

Decimal point indicates wirefeeder right side is active.

Decimal point indicates wirefeeder right side is active.


6-7. Typical Connection For Voltage-Sensing Feeder GMAW/GMAW-P/FCAW Process

804 843-B


1 Positive (+) Weld OutputTerminal


3 Ground Cable to Workpiece

4 Workpiece5 Voltage Sensing Clamp

6 Gun

7 Gun Trigger Receptacle

8 Wire Feeder

9 Gas Hose

10 Gas Cylinder

Use of shielding gas is dependanton Wire Type.

� The connection diagram illus-trates DCEP (reverse polarity)suitable for all wires exceptself-shielded FCAW. The ma-jority of self-shielded FCAWwires require DCEN (straightpolarity).

1

2

39

10

8

7

5

6

4


6-8. V-Sense Feeder Welding Mode - GMAW/FCAW Process

! Weld terminals are energized at alltimes in V-Sense Feeder weldingmode.

1 Mode Switch

2 Volts Indicator

3 Left Display

4 Right Display

5 Adjust Control



8 Setup Button


Setup

For typical system setup connections referto Section 6-7.

Rotate Mode Switch to V-SENSE FEEDERposition as shown.

The Left Display toggles between open cir-cuit voltage and preset voltage with theVolts Indicator lit.

Operation

While the Volts Indicator is lit under the LeftDisplay, the Adjust Control is used to setdesired preset voltage.

� The Left Display toggling momentarilypauses while the preset voltage is ad-justed.

Pressing the Setup Button allows adjust-ment of Arc Control, Wire Type, Gas Typeand preset voltage.

� For best results, select the appropriateWire and Gas Type to match the actualwire and gas being used.

Refer to MIG − Wire and Gas SelectionTable for available wires and gases (seeSection 6-3).







Arc Control (Inductance)

Press the Setup Button repeatedly until theArc Control indicator is lit. INDU appears onthe Left Display, and the corresponding in-ductance setting appears on the Right Dis-play.

Rotate Adjust Control to select desired in-ductance setting from 0 to 100. Use lowerinductance settings to stiffen the arc and re-duce puddle fluidity. Use higher inductancesettings to soften the arc and increasepuddle fluidity.

Refer to the MIG − Wire and Gas SelectionTable (see Section 6-3) for suggested in-ductance setting for the specific wire andgas being used.

� Each Wire and Gas Type combinationhas independent preset voltage and in-ductance settings. These settings arepreserved when the unit is turned off.

226 611-A1

5

5.02

432

6

7

8

9


6-9. V-Sense Feeder Welding Mode - GMAW-P Process

! Weld terminals are energized at alltimes in V-Sense Feeder weldingmode.

1 Mode Switch

2 Volts Indicator

3 Left Display

4 Right Display

5 Arc Length Indicator

6 Adjust Control



9 Setup Button


Setup

For typical system setup connections referto Section 6-7.

Rotate Mode Switch to V-SENSE FEEDERposition as shown.

The Left Display toggles between open cir-cuit voltage and the arc length setting. Theopen circuit voltage is shown while theVolts Indicator is lit, and the arc length set-ting is shown while the Arc Length Indicatoris lit.

Operation

While the Arc Length Indicator is lit underthe Left Display, the Adjust Control is usedto set desired arc length setting.

� The Left Display toggling momentarilypauses while the arc length setting isadjusted.

Pressing the Setup Button allows adjust-

ment of Arc Control, Wire Type, Gas Typeand Arc Length.

� For best results, select the appropriateWire and Gas Type to match the actualwire and gas being used.

Refer to Pulsed MIG − Wire and Gas Selec-tion Table for available wires and gases(see Section 6-5).







Arc Control (SharpArc)

Press the Setup Button repeatedly until theArc Control indicator is lit. SHRP appearson the Left Display, and the correspondingSharpArc setting appears on the Right Dis-play.

Rotate Adjust Control to select desiredSharpArc setting from 0 to 50, default is 25.Adjusting the SharpArc setting changes thewelding arc cone. Lower settings widen thearc cone, increases puddle fluidity and flat-tens the weld bead appearance.

Higher settings narrow the arc cone, re-duces puddle fluidity and crowns the weldbead appearance.

� Each Wire and Gas Type combinationhas independent Arc Length and Shar-pArc settings. These settings are pre-served when the unit is turned off.

Arc Length

Arc length corresponds to the level of ener-gy needed to burn off the welding electrode.As wire feed speed increases, a higher arclength setting is required to burn off theadditional wire. The arc length setting ap-pears in the Left Display when the ArcLength Indicator is lit. Arc length can be ad-justed from 0 to 100.

Prior to arc initiation, the unit displays theletter “R” and a reference wire speed (IPM)on the Right Display. The reference wirespeed can be used as a starting point forthe wire speed setting at the feeder. Thewire speed and arc length can then be fur-ther adjusted to achieve the desired arclength.

The Configuration Option Menu (see Sec-tion 4-3) can be used to change the ArcLength setting from 0 to 100 to average arcvoltage. Average arc voltage can be usedas an alternative method to set the PulsedMIG welding arc with the same parameters(voltage and wire speed) as a conventionalMIG arc. Lower voltage settings corre-spond to tighter arc lengths while highervoltage settings correspond to longer arclengths. If the voltage mode is selected, theaverage preset voltage will be displayed onthe Left Display with the Volts Indicator lit.

226 611-A1

6

5.02

432 5

R200

7

8

9

10


SECTION 7 − SMAW/CAC-A OPERATION

6

3

4

2

1

7-1. Typical Connection For SMAW And CAC-A Process

Ref. 804 842-B


1 Electrode Holder (Carbon Arc)

For CAC-A process connect car-bon arc cutting torch to to positiveweld output terminal.

2 Electrode Holder3 Positive (+) Weld Output

Terminal


Connect desired remote control toremote 14 receptacle as required.

5 Compressed Air LIne


7 Workpiece

5

7


7-2. CC Welding Mode - SMAW/CAC-A Process

! Weld terminals are energizedthrough the remote control in CCwelding mode.

1 Mode Switch2 Left Display

3 Right Display4 Amps Indicator5 Adjust Control6 Arc Control Indicator

7 Setup Button

Setup


Rotate Mode Switch to CC position asshown.

The preset amperage is shown in the RightDisplay with the Amps Indicator lit.

Operation

While the Amps Indicator is lit under theRight Display, the Adjust Control is used toset desired preset amperage.

A remote control is required to turn on theweld output.

� If the remote control has an amperageadjustment, the adjustment will func-tion as a percentage of the preset am-perage.

Pressing the Setup Button allows adjust-ment of Arc Control, Hot Start Current, andHot Start Time.

� For best results at the end of the weld,pull back the electrode quickly to extin-guish the arc.

Arc Control (Dig)Press the Setup Button so the Arc Controlindicator is lit. DIG appears on the Left Dis-play, and the corresponding dig setting ap-pears on the Right Display.Rotate Adjust Control to select desired digsetting from 0 to 100.Dig control allows the arc characteristics,soft versus stiff, to be changed for specificapplications and electrodes. Lower the digsetting for smooth running electrodes likeE7018 and increase the dig setting for stiff-er, more penetrating electrodes like E6010.Press the Setup Button repeatedly until theArc Control light goes out to return to ad-justment of preset amperage.

Programmable Hot Start

Press the Setup button repeatedly untilHOT.S appears on the left display. HOT.Sadjusts the Hot Start Amperage to AdaptiveHot Start (AUTO) or from Min (1) to Max(50). Adaptive Hot Start (AUTO) automatic-ally chooses a default amperage. The Min(1) setting results in no hot start amperage.Higher numbers result in higher start am-perage.

Press the Setup button again so HOT.T ap-pears on the left display. HOT.T adjusts theHot Start Time to Adaptive Hot Start(AUTO) or from Min (1) to Max (50). Adapt-ive Hot Start (AUTO) automaticallychooses a default time. The Min (1) settingresults in no hot start time. Higher numbersresult in longer start time.

Press the Setup button to return to adjust-ment of preset amperage.

� Use this mode for Air Carbon Arc(CAC−A) cutting and gouging. For bestresults, adjust dig setting to maximum.

1

52

7 226 611-A

58

3 4

6


7-3. Stick Welding Mode - SMAW/CAC-A Process

! Weld terminals are energized at alltimes in Stick welding mode.

1 Mode Switch2 Volts Indicator3 Left Display4 Right Display5 Amps Indicator6 Adjust Control7 Arc Control Indicator8 Setup ButtonSetupFor typical system connections refer toSection 7-1.Rotate Mode Switch to STICK position asshown.The open circuit voltage is shown in the LeftDisplay with the Volts Indicator lit, and thepreset amperage is shown in the Right Dis-play with the Amps Indicator lit.OperationWhile the Amps Indicator is lit under theRight Display, the Adjust Control is used toset desired preset amperage.Pressing the Setup Button allows adjust-ment of Arc Control, Hot Start Current, andHot Start Time.

� For best results at the end of the weld,pull back the electrode quickly to extin-guish the arc.

Arc Control (Dig)

Press the Setup Button so the Arc Controlindicator is lit. DIG appears on the Left Dis-play, and the corresponding dig setting ap-pears on the Right Display.

Rotate Adjust Control to select desired digsetting from 0 to 100.

Dig control allows the arc characteristics,soft versus stiff, to be changed for specificapplications and electrodes. Lower the digsetting for smooth running electrodes likeE7018 and increase the dig setting for stiff-er, more penetrating electrodes like E6010.

Press the Setup Button repeatedly until theArc Control light goes out to return to ad-justment of preset amperage.

Programmable Hot StartPress the Setup button repeatedly untilHOT.S appears on the left display. HOT.Sadjusts the Hot Start Amperage to AdaptiveHot Start (AUTO) or from Min (1) to Max(50). Adaptive Hot Start (AUTO) automatic-ally chooses a default amperage. The Min(1) setting results in no hot start amperage.Higher numbers result in higher start am-perage.Press the Setup button again so HOT.T ap-pears on the left display. HOT.T adjusts theHot Start Time to Adaptive Hot Start(AUTO) or from Min (1) to Max (50). Adapt-ive Hot Start (AUTO) automaticallychooses a default time. The Min (1) settingresults in no hot start time. Higher numbersresult in longer start time.Press the Setup button to return to adjust-ment of preset amperage.

� Use this mode for Air Carbon Arc(CAC−A) cutting and gouging. For bestresults, adjust dig setting to maximum.

1

63

8 226 611-A

587 2. 0

7

4 52


7-4. Optional Low Open Circuit Voltage (OCV) Welding ModesLow OCV Operation

The unit can be optionally config-ured for low open circuit voltage(OCV) operation in Stick andScratch Start TIG modes. When theunit is configured for low OCV op-eration only a low sensing voltage(approximately 15 VDC) is presentbetween the electrode and theworkpiece prior to the electrodetouching the workpiece. Consult aFactory Authorized Service Agentfor information regarding how toconfigure the unit for low OCV weld-ing operation.

Notes


Notes


SECTION 8 − THEORY OF OPERATION

Power Interconnect BoardPC2

Remote 14-Pin ReceptacleRC50

ArcControl

VoltmeterV

AmmeterA

Front Panel And Display Board PC3

Voltage/Amperage

Adjust

ProcessSelectorSwitch

WeldProcessControl

Positive (+) Output Voltage FeedbackNegative (−) Output Voltage Feedback

Ribbon Cable

24 VAC

115 VAC

Boost Gate Signal

OptionalAuxiliary Power

115 VACReceptacle

Input Boost InductorCurrent Feedback

Input Rectifier Voltage

Bus Voltage

CurrentTransformer

CT1

4 5 6

7 89

1 2 3

10

20

21 21

22 23

24

25 26

27 ♦

InverterModuleMod2

BusCapacitorsC12, C13

BoostSnubberInductor

L2

SnubberResistorModuleRM1

BoostInput

InductorL1

InputPre-Regulator

ModuleMod1

PowerSwitch

S1

1 Phaseor

3 PhaseInput

Power


Weld Circuit

Optional♦

StickBoost

RectifierSR1

StickBoost

InductorL4

StickBoostRelayCR1

MainTransformer

T1

OutputDiodes

D1 & D2

181716

1312

SeriesCapacitor

C15

11

OutputStabilizer

L3

Negative (−)Weld

OutputReceptacle

Work

1519

Positive (+)Weld

OutputReceptacleOutput

Current Sensor

HD1

1415

Electrode

OptionalGas

SolenoidGS1

FanMotor FM1

3536

Output Current Feedback

PrimaryHeatsink

ThermistorRT-2

SecondaryHeatsink

ThermistorRT-1

37 38

ControlTransformer

T2Supplementary

Protector CB2

SupplementaryProtector

CB1

32

33

34

115 VAC

24 VAC

34 VACCenterTapped

665VAC

Inverter Gating Signals

Main TransformerCurrent Feedback

BoostControl

ControlPower

Module

InverterControl

31

3029

28

Control BoardPC1

♦

Primary Circuit

Control Circuit

115 VAC


Theory Of Operation Components

1 Primary Input Power

Single or Three-Phase AC primarypower supply.

2 Power Switch S1

Provides on/off control of primaryinput power to welding powersource.

3 Power Interconnect BoardPC2

Provides electrical connections forL1, L2, MOD1, MOD2, RM1, C12 &C13. Precharge and bleeder resis-tors and snubber capacitors aremounted on PC2.

4 Boost Input Inductor L1

Required to boost input rectifiervoltage to bus voltage.

5 Boost Snubber Inductor L2

Required to ensure soft−switchingof the boost IGBT located inMOD1.

6 Inverter Module MOD2

Contains the main inverter IGBTs,snubber IGBTs, main boost diode,and two boost snubber diodes.

7 Input Pre−Regulator ModuleMOD1

Contains the input rectifier diodes,boost IGBT, and one boost snub-ber diode.

8 Snubber Resistor ModuleRM1

Contains one boost snubber resis-tor and one inverter snubber resis-tor.

9 Bus Capacitors C12 & C13

Stores energy and filters the DCbus voltage for input boost and in-verter.

10 Current Transformer CT1

Provides T1 current feedback toPC1. Used to protect inverterIGBTs in case of T1 primary over-current.

11 Series Capacitor C15

Provides protection against T1 sat-uration. Saturation occurs whenthe voltage across the transformeris not balanced. The unbalancedvoltage appears as a DC offsetvoltage across the transformer andcan cause a T1 primary overcur-rent. The capacitor protectsagainst this condition by blockingthe DC offset.

12 Main Transformer T1

Switching action of IGBTs in MOD2creates the AC voltage source forT1 primary. T1 secondary outputssupply power to the weld circuit.

13 Output Diodes D1, D2

Rectifies the main secondary out-put of T1.

14 Output Current Sensor HD1

Provides weld output current feed-back to PC1.

15 Positive (+) and Negative (−)Weld Output Receptacles

Provide weld output and allowchanging of output polarity.

16 Stick Boost Relay CR1

Provides on/off control of Stickboost output circuit.

17 Stick Boost Inductor L4

Limits current in the Stick boostoutput circuit.

18 Stick Boost Rectifier SR1

Rectifies the Stick boost secon-dary output of T1.

19 Output Stabilizer L3

Filters or smooths the DC weld out-put current.

20 User Interface Board PC3

Consists of Voltmeter V, AmmeterA, Arc Control, Voltage/AmperageAdjust, Remote 14−pin receptacle,Process Selector Switch, andWeld Process Control.

21 Voltmeter V, Ammeter A

See Section 4-1, Front Panel.

22 Arc Control

Controls Dig in Stick process or In-ductance in MIG process. SeeSection 4-1 Front Panel.

23 Voltage/Amperage Adjust

Selects weld output voltage or am-perage level. See Sections 4-1 and4-2.

24 Remote 14-Pin ReceptacleRC50

Provides connection for accessoryequipment. See Sections 4-1,Front Panel, and 3-5, Remote 14Receptacle Information.

25 Process Selector Switch

Selects weld process. See Section4-1, Front Panel.

26 Weld Process Control

Controls weld output by automati-cally adjusting output current com-mand signal to Inverter Control.

27 Optional Auxiliary Power 115VAC Receptacle

Provides connection for auxiliaryequipment to welding powersource.28 Control Board PC1Contains the boost control, controlpower module, and inverter con-trol.29 Boost ControlControls switching of boost IGBTin MOD1 to regulate L1 current andthe DC bus voltage.30 Control Power ModuleContains power supply for boostcontrol power, and inverter IGBTsto create AC voltage source for T2primary.31 Inverter ControlControls the main inverter andsnubber IGBTs within MOD2.Regulates the weld output currentto the value received from weldprocess controller. Provides powerto PC3. Drives fan motor and gasvalve. Provides interface betweenprimary and secondary thermis-tors and PC3.32 Supplementary Protector

CB1Provides overload protection forremote 14-pin 115 VAC power, andoptional 115 VAC receptacle.33 Supplementary Protector

CB2Provides overload protection forremote 14-pin 24 VAC power.34 Control Transformer T2Provides power to inverter controlon PC1, remote 14-pin receptacle,and optional 115 VAC receptacle.35 Fan Motor FM1Provides cooling of heatsinks andcomponents mounted inside windtunnel. The fan motor is thermo-statically controlled and only runswhen cooling is needed. Once unitis cooled to proper temperature,fan will continue to run for ten min-utes.36 Optional Gas Solenoid GS1Provides on/off flow of shieldinggas to the arc while TIG welding.37 Secondary Heatsink

Thermistor RT-1Monitors temperature of secon-dary heatsink for fan motor controland overtemperature shutdown.38 Primary Heatsink Thermistor

RT-2Monitors temperature of primaryheatsink for fan motor control andovertemperature shutdown.


SECTION 9 − TROUBLESHOOTING

9-1. Checking Unit Before Applying Power

! Although control board PC1 and power interconnect board PC2 are briefly checked here, more complete tests may be needed laterfor these parts. This procedure is simply to get a basic okay to power up unit.

! Measure voltage of input capacitors according to Section 9-2 and be sure voltage is near zero before touching any parts.

� The pre-power checks should be done if any of the following conditions exist:

the symptoms are unknown;

the unit is completely inoperative;

visual damage is found on any of the following components: capacitors C12 and C13, control board PC1, modules MOD1 and MOD2, interconnecting board PC2;

there is no output or limited output.

Notes

PRE-POWER CHECKS


Ref. 803 721-B / 907 161

9-2. Measuring Input Capacitor Voltage

! Turn Off welding powersource, and disconnect inputpower.

! Significant DC voltage canremain on capacitors afterunit is Off. Always check thevoltage as shown to be surethe input capacitors havedischarged before workingon unit.

Remove cover


2 Voltmeter

3 Capacitor C12

Measure the DC voltage acrossC12 (+) Positive Terminal and C12(−) Negative Terminal on PC2 asshown until voltage drops to near0 (zero) volts.

4 Capacitor C13

Measure the DC voltage acrossC13 (+) Positive Terminal and C13(−) Negative Terminal on PC2 asshown until voltage drops to near0 (zero) volts.

� If the capacitor voltage does notdrop to near zero after severalminutes, use a bleeder resistorof between 25 and 1000 ohms,at least 5 watts, #16 AWG 1000volts DC insulating rating wireto discharge the capacitor(s) .

5 Typical Bleeder Resistor

An example of a typical bleeder re-sistor is shown on this page.

Proceed with pre-power checks.

12

Positive (+) lead to C12 (+) terminal, Negative (−) lead to C12 (−) terminal

3

1

2

Positive (+) lead to C13 (+) terminal, Negative (−) lead to C13 (−) terminal

4

Test Equipment Needed:

Typical Bleeder Resistor

25 to 1000 ohm,5 watt resistor

#16 AWG 1000 volts DCinsulation rating, approx.3 in. (76 mm) leads

5

PRE-POWER CHECKS


1

9-3. Input Pre-Regulator Module (MOD1)

Ref. 907 161 / 246 337-A

! Read and follow safetyinformation in Section 9-1before proceeding.

! Wear an earth groundedwrist strap when perform-ing pre-power and poweroff checks. Remove wriststrap before performingany checks or procedureswith power applied to themachine.

� Board layout may differ fromthat shown.

1 MOD1

Visually inspect MOD1 for dam-age.

Check all measurements forMOD1 (see Section 9-4).

� If any of the measurementsdo not read correctly, replaceMOD1 and MOD2. If an inputSCR measures short also re-place PC2.

� MOD1 and MOD2 are differ-ent and must be installed inthe proper location.

Match the number on the side ofeach module to the number onPC2.� MOD1 is skiip 83 HEC� MOD2 is skiip 83 EC

The modules come as a kit with in-stallation instructions that need tobe followed entirely.

Continue to the end of thepre-power checks.


Component Side Of Board

−BUS

L1-L2

D12

TP1AC1

L1

AC2

AC3

K A

RC3

9-4. Input Pre-Regulator Module (MOD1) Test Point Values

Input Pre-Regulator Module MOD1 DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms

Boost IGBT −BUS L1-L2 0.20 - 0.90 N/A

Boost IGBT (w/Plug Removed From RC3) D12 Left −BUS N/A 100k

Boost Snubber Diode L1-L2 TP1 0.20 - 0.90 N/A

Input SCR L1 AC1 OL N/A



Input Diode −BUS AC1 0.20 - 0.90 N/A



Input Pre-Regulator Module MOD1 IGBT Tester Positive Lead - RED IGBT Tester Negative Lead - BLACK Gate

Boost IGBT (w/Plug Removed From RC3) L1-L2 −BUS RC3-2

PRE-POWER CHECKS


1

9-5. Inverter Module (MOD2)

Ref. 907 161 / 246 337-A


! Wear an earth groundedwrist strap when performingpre-power and power offchecks. Remove wrist strapbefore performing anychecks or procedures withpower applied to the ma-chine.

� Board layout may differ fromthat shown.

1 MOD2

Visually inspect MOD2 for damage.

Check all measurements for MOD2(see Section 9-6).

� If any of the measurements donot read correctly, replaceMOD2, MOD1.

� MOD1 and MOD2 are differ-ent and must be installed inthe proper location.

Match the number on the side ofeach module to the number on PC2.� MOD1 is skiip 83 HEC� MOD2 is skiip 83 EC

The modules come as a kit with in-stallation instructions that need tobe followed entirely.

Continue to the end of the pre-power checks.


Component Side Of Board

HF-XFMR

TP3

L2

+BUS

−BUS

TP1

TP4

TP2

RC1

9-6. Inverter Module (MOD2) Test Point Values

Inverter Module MOD2 DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms

Boost Snubber Diode TP1 TP4 0.20 - 0.90 N/A

Boost Snubber Diode L2 TP4 0.20 - 0.90 N/A

Main Boost Diode TP4 +BUS 0.20 - 0.90 N/A

Inverter IGBT HF-XFMR +BUS 0.20 - 0.90 N/A

Inverter IGBT −BUS HF-XFMR 0.20 - 0.90 N/A

Snubber IGBT TP2 HF-XFMR 0.20 - 0.90 N/A

Snubber IGBT TP2 TP3 0.20 - 0.90 N/A

Inverter IGBT Gate (w/Plug Removed From RC1) RC1-1 HF-XFMR N/A 100k

Inverter IGBT Gate (w/Plug Removed From RC1) RC1-6 −BUS N/A 100k

Snubber IGBT Gate (w/Plug Removed From RC1) RC1-10 TP2 N/A 100k

Snubber IGBT Gate (w/Plug Removed From RC1) RC1-9 TP2 N/A 100k

Input Pre-Regulator Module MOD2 IGBT Tester Positive Lead - RED IGBT Tester Negative Lead - BLACK Gate

Inverter IGBT (w/Plug Removed From RC1) HF-XFMR −BUS RC1-6

Inverter IGBT (w/Plug Removed From RC1) +BUS HF-XFMR RC1-1

Snubber IGBT (w/Plug Removed From RC1) HF-XFMR D9 Left RC1-10

Snubber IGBT (w/Plug Removed From RC1) TP3 D9 Left RC1-9

PRE-POWER CHECKS


! Read and follow safety informationin Section 9-1 before proceeding.

! Wear an earth grounded wriststrap when performing pre-powerand power off checks. Removewrist strap before performing anychecks or procedures with power

applied to the machine.

1 Power Interconnect Board PC2

2 MOD1 And MOD2 ConnectingScrews Initial Torque to (9 in. lbs (1 N.m)Final Torque to (20 in. lbs (2.3 N.m)

All other connecting screws torque to(20 in. lbs (2.3 N.m)

Visually inspect PC2 for damage.Check all measurements for PC2 (seeSection 9-28).

� If any measurements failed, replacePC2 and bus capacitors.

9-7. Power Interconnect Board PC2


Ref. 907 161 / 246 337-A

1

R8R1

2

9-8. Power Interconnect Board PC2 Test Point Values

Power Interconnect Board PC2 DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms

Bleeder Resistor R1 Center Bus −BUS N/A 28k - 32k

Bleeder Resistor R8 +BUS Center Bus N/A 28k - 32k

Because R1 and R8 are connected to capacitors C12 and C13 the resistance measurements will require several minutes to complete. A moreprecise method would be to isolate R1 and R8 from the circuit. Perform this by removing the four connecting screws to C12 and C13 then slidepaper between the capacitors and PC2. If any of the measurements do not read correctly, replace PC2, capacitors C12 and C13. Continue tothe end of the pre-power checks.

PRE-POWER CHECKS


9-9. Control Board PC1

Ref. 907 161 / 242 814-C


! Wear an earth grounded wriststrap when performing pre-powerand power off checks. Removewrist strap before performing any

checks or procedures with powerapplied to the machine.

� Remove all plugs from PC1 beforetesting.

1 Control Board PC1

Visually inspect PC1 for damage.

Check all measurements for PC1.(see Section 9-10).

� If any of the measurements do not readcorrectly, replace PC1.


1

Test Equipment Needed:1

2

3

4

8

7

6

5

� Pin sequence of IC chips.

D46KA

RC

2

RC3

RC5

9-10. Control Board PC1 − Test Point Values

Pre-Regulator Control DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms

Buck IGBT D46 Anode RC2 Pin 1 0.20 - 0.90 N/A

Buck Diode RC3 Pin 6 U6 Pin 5 0.20 - 0.90 N/A

Boost IGBT Gate Drive RC3 Pin 4 RC3 Pin 2 0.20 - 1.50 N/A

Boost IGBT Gate Drive RC3 Pin 4 RC3 Pin 3 N/A 1.9k - 2.1k

Boost IGBT Gate Drive RC3 Pin 3 RC3 Pin 4 0.20 - 0.90 N/A

60Hz Auxiliary Power Bridge DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms

Auxiliary Bridge IGBT RC5 Pin 3 RC2 Pin 1 0.20 - 0.90 N/A




PRE-POWER CHECKS


9-11. Power Switch (S1)

Ref. 907 161 / Ref. 183 484



1 Power Switch S1

Visually inspect S1 for damage.

Check switch mechanical opera-tion by turning switch On and Offseveral times. Switch should snapsharply between the On and Off po-sitions.

Check switch electrical operationby checking continuity across S1contacts with switch in the On posi-tion. With switch in the Off position,ohmmeter should read open.

Replace switch if necessary.



1

Electrical Schematic

PRE-POWER CHECKS


9-12. Output Diodes D1, D2

Ref. 804 980-A / 804 979-ADiodes D1, D2

−

Weld OutputReceptacles

+



1 Diode D1

2 Diode D2

Visually inspect D1 and D2 for dam-age.

Check all measurements for outputdiodes D1 and D2 (see Section9-13).

� If any of the measurements donot read correctly, replace bothD1 and D2.


2

1


9-13. Output Diodes D1, D2 Test Point Values

Output Diodes D1 And D2 DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms

D1 Terminal Anode Secondary Heatsink 0.10 - 0.90 N/A

D2 Terminal Anode Secondary Heatsink 0.10 - 0.90 N/A

PRE-POWER CHECKS


9-14. Stick Boost Rectifier (SR1)

Ref. 804 980-A / 804 979-A



1 Stick Boost Rectifier SR1

Visually inspect SR1 for damage.

Check all measurements for SR1(see Section 9-15).

� If any of the measurements donot read correctly, replaceSR1.

3

4

2

1


1

9-15. Stick Boost Rectifier (SR1) Test Point Values

Stick Boost Rectifier SR1 DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms

SR1 Terminal 2 Terminal 1 0.20 - 0.90 N/A




Always check unit before applying power (see Sections 9-1 thru 9-10).


9-16. Troubleshooting Table

! Remove earth grounded wrist strap beforeperforming any checks or procedures withpower applied to the machine.

� See Section 9-18 for test points and values andSection 12 for parts location.

� Use MILLER Testing Booklet (Part No. 150 853)when servicing this unit.

� See the MILLER Extranet for service memos thatmay aid in the repair of this product.

Trouble Remedy

No weld output; unit completelyinoperative.

Place line disconnect switch in On position (see Section 3-9 or 3-10).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Sections 3-9 and 3-10).

Check for proper input power connections and check condition of power cord (see Section 3-9 or 3-10).

Check continuity of Power switch S1 and replace if necessary (see Section 9-11).

Check control transformer T2 for signs of winding failure. Check continuity across windings, andcheck for proper connections. Check secondary voltages. Replace T2 if necessary.

Check control board PC1 and connections, and replace if necessary (see Power Off Checks in Sec-tions 9-21 thru 9-22, and also see Section 9-19).

Check power interconnect board PC2 and connections, and replace if necessary (see Power OffChecks in Sections 9-27 thru 9-28, and also see Section 9-25).

Check front panel/display board PC3 and connections, and replace if necessary (see Section 9-31).

No weld output; meter display On. Unit overheated and HELP 3 or HELP 5 screen is displayed. Allow unit to cool with fan On (see Section 2-4).

If a remote accessory is connected to remote 14 receptacle RC50:

Check accessory contact closure (continuity), and replace accessory if necessary.

Check accessory amperage control potentiometer resistance and connections, and replace accessory if necessary.

Check input and output voltages of hall device HD1 (see Section 9-18). Replace HD1 if necessary.



Low weld output with no control. Check input and output voltages of hall device HD1 (see Section 9-18). Replace HD1 if necessary.



Maximum weld output with no control. Check input and output voltages of hall device HD1 (see Section 9-18). Replace HD1 if necessary.



Limited output and low open circuitvoltage (OCV).

Check for proper input and output connections


Check accessory contact closure (continuity), and replace accessory if necessary.

Check accessory amperage control potentiometer resistance and connections, and replace accessory if necessary.




Trouble Remedy

Limited output and low open circuitvoltage (OCV). (Continued)

Check if Low Open Circuit Mode Operation is enabled (see Section 7-4).



Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-4).

Clean and tighten all weld connections.

Check for proper input and output connections.

Replace electrode.


Check all remote accessory connections (proper pin/socket alignment).

Check accessory amperage control potentiometer resistance and connections, and replace if necessary.




No 24 volt AC output at Remote 14 re-ceptacle RC50.

Reset supplementary protector CB2 if necessary (see Section 3-6).

Check receptacle wiring and connections.

No 115 volt AC output at Remote 14receptacle RC50 or optional duplex re-ceptacle RC2.

Reset supplementary protector CB1 if necessary (see Section 3-6).

Check receptacle wiring and connections.

Fan motor does not run after approxi-mately four minutes of operation atrated load.

Check and clear blocked fan blade

Check receptacle wiring and connections. Check thermistors RT-1 and RT-2 (see Section 9-18).

� Fan motor FM1 starts and meters display HELP-2 when RT-1 or RT-2 is disconnected from PC1.When RT-1 or RT-2 is reconnected, the meter displays change but the fan continues to run (see Sec-tion 9-17).

Check fan motor FM (see Section 9-18) and replace fan motor if necessary.

Wandering arc; poor control of arcdirection.

Use proper size tungsten.

Use properly prepared tungsten.

Reduce gas flow rate.

Tungsten electrode oxidizing and notremaining bright after conclusion ofweld.

Shield weld zone from drafts.

Increase postflow time.

Check and tighten all gas fittings.

Water in torch. Refer to torch manual.



9-17. Help Displays

� All directions are in reference to the frontof the unit. All circuitry referred to is lo-cated inside the unit.

Help 1 Display

Indicates a malfunction in the primary powercircuit. If this display is shown, contact a Fac-tory Authorized Service Agent.

Help 2 Display

Indicates a malfunction in the thermal protec-tion circuitry. If this display is shown, contacta Factory Authorized Service Agent.

Help 3 Display

Indicates the left side of the unit has over-heated. The unit has shut down to allow thefan to cool it (see Section 2-4). Operation willcontinue when the unit has cooled.

Help 5 Display

Indicates the right side of the unit has over-heated. The unit has shut down to allow thefan to cool it (see Section 2-4). Operation willcontinue when the unit has cooled.

Help 6 Display

Indicates operation at maximum input cur-rent. The unit has a maximum allowable inputcurrent limit. As the line voltage decreases,the required input current increases. If the linevoltage is too low, the output power is limitedby the input current. When this limit isreached, the unit automatically reduces out-put power to continue operation. If this displayis shown, have a qualified electrician checkthe input voltage.

Help 8 Display

Indicates a malfunction in the secondarypower circuit of the unit. If this display isshown, contact a Factory Authorized ServiceAgent.

Help 25 Display

Indicates machine has reached duty cyclelimits (see Section 2-4). Unit must be left onto power the fan for cooling. Operation willcontinue when unit has cooled.

HELP 1

2

3

5

6

8

HELP

HELP

HELP

HELP

HELP

25HELP



Notes

2298

95

MATERIAL THICKNESS GAUGE



! HIGH VOLTAGE: Do not measure withoutproper instrumentation.

! Measure voltage of input capacitors ac-cording to Section 9-2, and be sure voltageis near zero before touching any parts.

Voltage Readings

a) Tolerance − ±10% unless specified

b) Reference − single arrow: reference tocircuit common (lead 42); double arrow:reference to points indicated

c) Wiring Diagram − see Section 11

V1 665 volts AC RMS

V2, V3 17 volts AC RMS

V4 115 volts AC RMS

V5 24 volts AC RMS

V6, V7 470 volts DC

V8 115 volts AC RMS when FM is running

V9 24 volts DC when Relay is energized;Relay energized in Stick mode withoutput current greater than 10 ampsand preset current less than 225 amps

V10 24 volts DC when gas is flowing; seeSection 3-7 for gas valve operation

V11 +15 volts DC

V12 −15 volts DC

V13 1 volt DC per 100 amperes of weldoutput

V14 72 volts DC open circuit voltage inScratch Start TIG, TIG, MIG, PulseMIG, CC, Stick and V-Sense feedermodes.

9-18. Troubleshooting Circuit Diagram

� No calibration available for voltmeter V or ammeter A.


See Section 9-32 forRC50 information

See Section 9-31 forPC3 information

V14

V5

V4 V3 V2 V1

Resistance Values


b) Turn Off unit and disconnect input powerbefore checking resistance

R1 thru R6, R9 Less than 1 ohm

R7 and R8 190 − 210 ohms

� V1 thru V5 and V8 − use only true RMS meterto obtain correct voltage reading.

� 14 volts DC in Stick and ScratchStart TIG modes (Effective withMA100311A) when low open cir-cuit voltage mode is enabled(See Section 7-4).



R5

R9

256 234-A

R6

R3

See Section 9-19 forPC1 information

V6

R1

V8

See Section9-25 for

PC2 information

R2 R7 R8

R4

V7

V9

V10

Approx. 35K ohmsat 70� F (21� C)

V13

V12V11

V14

{



9-19. Control Board PC1 Testing Information (Use with Section 9-20)

Ref. 242 814-C / 907 161

! Measure voltage of input ca-pacitors according to Section9-2, and be sure voltage is nearzero before touching anyparts.

Be sure plugs are secure before ap-plying power. See Section 9-20 forspecific values during testing.

1 Control Board PC1


1



9-20. Control Board PC1 Test Point Values


b) Reference − to circuit common(lead 42) unless noted

PC1 Voltage Readings

Receptacle Pin Type Value

RC1! Do not measure − high voltage present.

RC2 ! High voltage present. Voltages on this receptacle can exceed 900 volts DC from chassis (GND).

NOTE: All pins on this receptacle are referenced to the primary − Bus

1 Input Primary (+) bus; regulated to 940 volts DC with respect to primary (−) bus.

2 Not used

3 Not used

4 Input Primary (+) rectifier; rectified primary line volts.

RC3! High voltage present. Voltages on this receptacle can exceed 900 volts DC from chassis (GND).


1 Input Do not measure − Boost inductor current feedback; 1 volt DC per 16 amps of boost inductor current

2 Output +15 volts DC; regulated with respect to primary (−) bus

3 Output −12 volts DC; regulated with respect to primary (−) bus

4 Output Do not measure − Boost IGBT gate drive signal

5 Do not measure − Boost IGBT gate drive signal return

6 Precom Circuit common referenced to primary (−) bus



9 Input Do not measure − Main transformer current sense CT; senses overcurrent in T1 transformer primary

10 Do not measure − Main transformer current sense CT return

11 Output Precharge relay coil return; 0 volts DC = relay contacts open, −12 volts DC = relay contacts closed withrespect to primary (−) bus

12 Not used

13 Input Do not measure − Test point, used to test board only

14 Input Do not measure − Test point, used to test board only



1 Output Control transformer primary; 665 volts AC RMS with respect to RC5 pin 3

2 Not Used

3 Output Control transformer primary; 665 volts AC RMS with respect to RC5 pin 1



Section 9-20. Control Board PC1 Test Point Values (Continued)


RC6 1 Input Output reference; 1 volt DC per 42.5 amperes of weld output when machine is under load; when modeswitch in TIG mode, adjust control set at minimum = 0 volts DC, adjust control set at maximum = 10 voltsDC

2 Input Voltage feedback; 1 volt DC per 10 volts DC of weld output

3 Output Current feedback; 1 volt DC per 100 amperes of weld output

4 Not Used

5 Input Output enable; 0 volts DC = ON, +12.5 volts DC = OFF

6 Not Used

7 Boost relay coil return; +24 volts DC = relay contacts open, less than +1 volts DC = relay contacts closed

8 Gas valve coil return; +24 volts DC = valve closed (no gas flow), less than +1 volts DC = valve open

9 Input Fan enable; +5 volts DC = fan on, −15 volts DC = fan off

10 Not Used

11 Output Main transformer overcurrent detect; +.7 volts DC = OK, +3.3 volts DC = T1 primary overcurrent = HELP1

12 Not Used

13 Input +3.0 volts DC reference voltage for thermistors

14 GND Circuit common referenced to chassis

15 Output Secondary side thermistor return; +1.2 volts DC at 25°C thermistor temperature (Prior To LJ400071A +.473 volts DC)


17 Output Primary side thermistor return; +1.2 volts DC at 25°C thermistor temperature (Prior To LJ400071A +.473 volts DC)


19 Output Foldback; decreases weld output if input bus voltage drops, 0 volts = OK, +15 volts DC 15Khz pwmsquarewave = foldback


21 Output +24 volts DC, unregulated DC voltage with respect to GND

22 Output +24 volts DC, unregulated DC voltage with respect to GND

23 Output −24 volts DC, unregulated DC voltage with respect to GND

24 Output −24 volts DC, unregulated DC voltage with respect to GND

RC7 1 Output +3 volts DC reference voltage for secondary side thermistor

2 Input Secondary side thermistor return; +1.2 volts DC at 25°C thermistor temperature (Prior To LJ400071A +.473 volts DC)

RC8 1 Output +3 volts DC reference voltage for primary side thermistor

2 Input Primary side thermistor return; +1.2 volts DC at 25°C thermistor temperature (Prior To LJ400071A +.473 volts DC)



Section 9-20. Control Board PC1 Test Point Values (Continued)

RC9 1 Output Do not measure − Test point, used to test board only

2 Output Do not measure − Test point, used to test board only

3 Input Do not measure − Weld output current sensor signal

4 Output +15 volts DC power to current sensor

5 Output −15 volts DC power to current sensor

6 GND Weld output current sensor signal common

RC10 1 Output 115 volts AC RMS with respect to GND; power feed to fan

2 Output Fan power return; measure with respect to RC10−1, 115 volts AC RMS = fan on, less than 20 volts ACRMS = fan off



RC11 1 Output +24 volts output to boost relay coil


3 Output +24 volts output to gas valve coil


RC12 1 Not Used

2 Input 34 volts AC RMS; measure with respect to RC12 pin 4, power supply used to create +24/−24 volts DC

3 Chassis Power source chassis; circuit common (GND) on this pin bonded to chassis thru wire

4 Input 34 volts AC RMS; measure with respect to RC12 pin 2, power supply used to create +24/−24 volts DC

5 Not Used

6 Input Center tap of 34 volt AC connected to circuit common (GND) on board

7 Not Used

8 Input 115 volts AC RMS

Notes

OHM'S LAW

VOLTAGE =

CURRENT X RESISTANCE

CURRENT = VOLTAGE

RESISTANCE

RESISTANCE = VOLTAGE

CURRENT



9-21. Control Board PC1 − Power Off Checks (Prior To MA070470A)

Ref. 220 468-C / 907 161


! Wear an earth grounded wriststrap when performing power offchecks. Remove wrist strap before

performing any checks or proce-dures with power applied to themachine.

� Remove all plugs from PC1 before testing.

1 Control Board PC1

Check all measurements for PC1.

� If any measurements failed, replacePC1.


1

2

3

4

8

7

6

5


D39

D38

D43

D44

D46

D51

D49

D38

U6

KA

RC5U5U4

KA

D37 D42D41U11

D20D11D18

KA

RC3U17

RC9

U16

U13



9-22. Control Board PC1 − Power Off Checks (Prior To MA070470A)


Buck IGBT Gate Drive IC U6 U6 Pin 6 U6 Pin 7 0.20 - 0.90 N/A

Inverter Control DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms

Inverter IGBT Gate Drive IC U16 RC9 Pin 6 U16 Pin 5 0.20 - 0.90 N/A






Inverter IGBT Gate Drive IC U16 U16 Pin 5 RC9 Pin 4 0.20 - 0.90 N/A







Auxiliary Bridge IGBT Gate Drive IC U1 RC3 Pin 6 (PRECOM) U1 Pin 5 0.20 - 0.90 N/A

Auxiliary Bridge IGBT Gate Drive IC U1 U1 Pin 5 U1 Pin 6 0.20 - 0.90 N/A



Auxiliary Bridge IGBT Gate Drive IC U4 RC5 Pin 1 U5 Pin 7 0.20 - 0.90 N/A


D37 D37 Anode D37 Cathode 0.20 - 0.90 N/A















9-23. Control Board PC1 - Power Off Checks (Effective With MA070470A)

Ref. 242 814-C / 907 161


! Wear an earth grounded wriststrap when performing power offchecks. Remove wrist strap before

performing any checks or proce-dures with power applied to themachine.

� Remove all plugs from PC1 before testing.

1 Control Board PC1

Check all measurements for PC1.


Test Equipment Needed:1

2

3

4

8

7

6

5


D39

D38

D43

KA

D44

KA

1

RC3

RC9

U17

U16

U13

RC5U5U4U1

D61

D46

D51

D49

D37 D42D41

D38

D20D11D18

KA

U6



9-24. Control Board PC1 − Power Off Checks (Effective With MA070470A)


Buck IGBT Gate Drive IC U6 U6 Pin 6 U6 Pin 7 0.10 - 0.30 N/A

Inverter Control DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms





Snubber IGBT Gate Drive IC U13 RC9 Pin 6 U13 Pin 5 0.10 - 0.30 N/A

Snubber IGBT Gate Drive IC U13 RC9 Pin 6 U13 Pin 7 0.10 - 0.30 N/A





Snubber IGBT Gate Drive IC U13 U13 Pin 5 RC9 Pin 4 0.10 - 0.30 N/A

Snubber IGBT Gate Drive IC U13 U13 Pin 7 RC9 Pin 4 0.10 - 0.30 N/A
























9-25. Power Interconnect Board PC2 Testing Information (Use with Section 9-26)

Ref. 246 337-A / 907 161

! Measure voltage of inputcapacitors according toSection 9-2, and be surevoltage is near zero be-fore touching any parts.

Be sure plugs are secure beforeapplying power. See Section9-26 for specific values duringtesting.



1



9-26. Power Interconnect Board PC2 Test Point Values

PC2 Voltage Readingsa) Tolerance − ±10% unless specified



RC1! Do not measure − high voltage present.



1 Output Primary (+) bus; regulated to 940 volts DC with respect to primary (−) bus

2 Not Used

3 Not Used

4 Output Primary (+) rectifier; rectified primary line volts



1 Do not measure − Boost IGBT gate drive signal return

2 Input Do not measure − Boost IGBT gate drive signal

3 Output Do not measure − Boost inductor current feedback

4 Input −12 volts DC; regulated with respect to primary (−) bus, −12 volts DC power to boost inductor current sensor



7 Input Precharge relay coil return; 0 volts DC = relay contacts open, −12 volts DC = relay contacts closed withrespect to primary (−) bus

8 Input +15 volts DC; regulated with respect to primary (−) bus, +15 volts DC power to boost inductor current sensor



1 Snubber resistor1; input boost snubber, located in resistor module mounted to primary heat sink

2 Not Used

3 Snubber resistor2; inverter snubber, located in resistor module mounted to primary heat sink

4 Snubber resistor1; input boost snubber, located in resistor module mounted to primary heat sink

5 Not Used

6 Snubber resistor2; inverter snubber, located in resistor module mounted to primary heat sink



Section 9-26. Power Interconnect Board PC2 Test Point Values (Continued)

! High voltage present. The following terminals are used to interconnect the main power circuit withthe primary supply, and with power circuit components not soldered in the pcb. Voltages on thisreceptacle can exceed 900 volts DC from chassis (GND).


AC1 Power Primary AC mains phase 1; line voltage, measure with respect to AC2 or AC3



L1 Power Input boost inductor; rectified line voltage, measure with respect to (−) bus

L1-L2 Power Common point between input boost inductor and boost IGBT snubber inductor

L2 Power Boost IGBT snubber inductor

HF-XFMR Power High frequency weld power transformer primary

C13 (+) Power (+) Bus; regulated to 940 volts DC with respect to (−) bus

C12 (−) Power (−) Bus; power circuit common

Center Bus Power Bus capacitors center point; regulated to 470 volts DC with respect to (−) bus

Notes

16 Gauge (.063 in)

22 Gauge (.031 in)

24 Gauge (.025 in)

20 Gauge (.037 in)

18 Gauge (.050 in)

14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

MATERIAL THICKNESS REFERENCE CHART



Notes

2298

95

MATERIAL THICKNESS GAUGE



9-27. Power Interconnect Board (PC2) - Power Off Checks (Prior To MB510232A)

Ref. 907 161 / 232 403-B


! Wear an earth grounded wriststrap when performing power offchecks. Remove wrist strap beforeperforming any checks or proce-

dures with power applied to themachine.




Check all measurements for PC2 (see Section 9-28).


1


AC3

R14

D13

D12

R11

R12

R10

AC1

AC2

K A

D11 D10

D8

D9

Q1

D1

D2

D3

D4

K A

−BUSCenterBus Q2+BUS



9-28. Power Interconnect Board (PC2) - Power Off Checks (Prior To MB510232A)


Pre-Charge Resistor R14 R14 Bottom R14 Top N/A 200

SCR Gate Resistor R10 R10 Left R10 Right N/A 10 - 16.5



Pre-Charge Diode D5 AC3 R14 Top 0.20 - 0.90 N/A



Boost Gate Protection Diode D12 D12 Anode D12 Cathode 0.20 - 0.90 N/A

Boost Gate Protection Diode D13 D13 Anode D13 Cathode 0.20 - 0.90 N/A

Inverter Gate MOSFET Q1 Q1-S (Source) Q1-D (Drain) 0.20 - 0.90 N/A


Inverter Gate Protection Diode D1 D1 Anode D1 Cathode 0.20 - 0.90 N/A




Snubber Gate Protection Diode D8 D8 Anode D8 Cathode 0.20 - 0.90 N/A




Notes




! Wear an earth grounded wriststrap when performing power offchecks. Remove wrist strap beforeperforming any checks or proce-

dures with power applied to themachine.




Check all measurements for PC2 (see Section 9-28).


9-29. Power Interconnect Board (PC2) - Power Off Checks (Effective With MB510232A)

Ref. 907 161 / 246 337-A

1


AC3

R14

D12

R11

R12

R10

AC1

AC2

Q2

D9

Q1

D1

D2

D3

K A

K A



9-30. Power Interconnect Board (PC2) - Power Off Checks (Effective With MB510232A)


Pre-Charge Resistor R14 R14 Bottom R14 Top N/A 200







Boost Gate Protection Diode D12 D12 Left D12 Right N/A 100k



Inverter Gate Protection Diode D2 D2 Left D2 Right N/A 100k

Inverter Gate Protection Diode D3 D3 Left D3 Right N/A 100k

Snubber Gate Protection Diode D9 D9 Left D9 Right N/A 100k

Notes



9-31. Front Panel/Display Board PC3 Testing Information (Use with Section 9-32)

Ref. 242 727-C / 804 980-A

! Measure voltage of inputcapacitors according toSection 9-2, and be surevoltage is near zero beforetouching any parts.

Be sure plugs are secure before ap-plying power. See Section 9-32 forspecific values during testing.

1 Front Panel/Display BoardPC3


1



9-32. Front Panel/Display Board PC3 Test Point Values

PC3 Voltage Readingsa) Tolerance − ±10% unless specified



RC1 1 Output Output reference; 1 volt DC per 42.5 amperes of weld output when machine is under load; when modeswitch in TIG mode, adjust control set at minimum = 0 volts DC, adjust control set at maximum = 10 voltsDC

2 Output Voltage feedback; 1 volt DC per 10 volts DC of weld output

3 Input Current feedback; 1 volt DC per 100 amperes of weld output

4 Not Used

5 Output Output enable; 0 volts DC = ON, +12.5 volts DC = OFF

6 Not Used



9 Output Fan enable; +5 volts DC = fan on, −15 volts DC = fan off

10 Not Used

11 Input Main transformer overcurrent detect; +.7 volts DC = OK, +3.3 volts DC = T1 primary current = HELP 1

12 Not Used

13 Output +3.0 volts DC reference voltage for thermistors


15 Input Secondary side thermistor return; +1.2 volts DC at 25°C thermistor temperature (Prior To LJ400071A +.473 volts DC)


17 Input Primary side thermistor return; +1.2 volts DC at 25°C thermistor temperature (Prior To LJ400071A +.473 volts DC)


19 Input Foldback; decreases weld output if input bus voltage drops, 0 volts = OK, +15 volts DC 15Khz pwmsquarewave = foldback


21 Input +24 volts DC, unregulated DC voltage with respect to GND, power feed to front panel pcb

22 Input +24 volts DC, unregulated DC voltage with respect to GND, power feed to front panel pcb

23 Input −24 volts DC, unregulated DC voltage with respect to GND, power feed to front panel pcb

24 Input −24 volts DC, unregulated DC voltage with respect to GND, power feed to front panel pcb

RC2 1 Input Negative weld output terminal; used for output voltage feedback

2 Not Used

3 Input Positive weld output terminal; used for output voltage feedback



Section 9-32. Front Panel/Display Board PC3 Test Point Values (Continued)


RC50 A Output 23 volts AC RMS at 10 amps; 14−pin remote accessory power

B Input Remote output enable; 0 volts AC = weld output off, 23 volts AC RMS = weld output on

C Output Output signal to remote command reference; +10 volts DC

D GND Remote command reference signal common

E Input Input signal from remote command; 0 to 10 volts DC, +13.5 volts DC when not connected to remote com-mand from accessory

F Output Current feedback; 1 volt DC per 100 amperes of weld output

G GND 14−pin remote accessory power return

H Output Voltage feedback; 1 volt DC per 10 volts DC of weld output

I Output 115 volts AC RMS at 2 amps; 14−pin remote accessory power

J Input Remote output enable; 0 volts AC = weld output off, 115 volts AC RMS = weld output on

K Chassis Power source chassis

L Input Wirefeed command. 0 to +10 volts DC from synergic capable wire feeder

M Input Prior to MA370426A not used. Effective with MA370426A Remote Process Select. When connected toRemote Process Select capable single wirefeeder; Mig = 3.5 volts DC, Pulse = 2.5 volts DC. When con-nected to Remote Process Select capable dual wirefeeder; left side Mig = 5.5 volts DC, left side Pulse =4.5 volts DC, right side Mig = 7.5 volts DC, right side Pulse = 6.5 volts DC

N Input Wirefeed speed common

9-33. Checking Unit Output After Servicing

803 691-C

1 Weld Output Terminals

Check open-circuit voltage be-tween terminals according to Sec-tion 9-18 (voltage V-14)

If correct voltage is not present,repeat troubleshooting procedures.

Reinstall cover and side panels ifremoved.

1



9-34. Enabling Low Open Circuit Voltage Welding Modes (Optional) EffectiveW/MA100311A

907 161-A / 242 727-C

! Disconnect and lockout/tag-out input power before re-moving cover.

Follow this procedure to configurethe unit for low open circuit voltage(OCV) operation in Stick andScratch Start Tig modes. OCV isreduced to about 15 volts DC.

1 Front Panel And DisplayBoard PC3

Remove wrapper.

Place switch position 1 in theClosed position by pressing actua-tor toward board.

Reinstall wrapper.

1


SECTION 10 − MAINTENANCE

10-1. Routine Maintenance

� Maintain more oftenduring severe conditions.

! Disconnect power before maintaining.

3 Months

ReplaceDamaged OrUnreadable

Labels

Replace CrackedTorch Body

Repair OrReplaceCrackedCables

Repair Or ReplaceCracked Cables

And Cords

CleanAnd

Tighten WeldConnections

6 Months

Blow Out Inside

10-2. Blowing Out Inside Of Unit

! Do not remove case whenblowing out inside of unit.

To blow out unit, direct airflowthrough front and back louvers asshown.

Blowing Out Unit 2010−01

TM-2247 Page 73XMT 350 Auto Line

10-3. Removing Fan Motor

! Significant DC voltage canremain on capacitors afterunit is Off. Always checkcapacitors according toSection 9-2 to be sure theyhave discharged beforeworking on unit.

� Drawing is representative andmay not reflect actual unit.

1 Mounting Unit Foot

2 Base

3 Fan Motor

4 Louver

Remove wrapper from unit.

Place unit upside down on securework area as shown.

Remove mounting unit feet.

Lift off base.

Remove louver from front panel as-sembly.

Remove bolts (2) securing fan as-sembly.

Disconnect fan motor plug and re-move fan from unit.

Reverse steps to replace fan motorin unit.

Tools Needed:

1/2, 9/16 in.

805 299-A

1

5/16 in.

2

3

4


Notes


SECTION 11 − ELECTRICAL DIAGRAMS

� The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuitinside machine case or contact distributor for more information.

The following is a list of all diagrams for models covered by this manual.

Model Serial Or Style Number Circuit Diagram Wiring Diagram

XMT 350 MPa(208 − 575 Volt Models)

LJ410832A thru MA370425A 231 442-B 231 458-A

MA370426A thru MB380678A 249 903-A 231 458-A

MB380679A thru MB520505A 254 090-A 256 241-A

MB520506A and following 256 234-A 256 241-A

Circuit Board PC1(Control W/Program)

LJ410832A thru MA070469A 220 469-B♦♦

MA070470A and following 242 816-D♦♦

Circuit Board PC2(Power Interconnect)

LJ410832A thru MB510231A 225 066-C♦♦

MB510232A and following 246 338-A♦♦

Circuit Board PC3(Front Panel/Display)

LJ410832A thru MA060330P 225 684-E♦♦

MA060331P and following 244 285-B♦♦

♦♦ Not included in this manual


Figure 11-1. Circuit for XMT 350 MPa (208 − 575 Volt) Eff. w/LJ410832A Thru MA3704525A


231 442-B


Figure 11-2. Circuit for XMT 350 MPa (208 − 575 Volt) Eff. w/MA370426A Thru MB380678A


249 903-A


Figure 11-3. Circuit for XMT 350 MPa (208 − 575 Volt) Eff. w/MB380679A Thru MB520505A


254 090-A


Figure 11-4. Circuit for XMT 350 MPa (208 − 575 Volt) Eff. w/MB520506A And Following


256 234-A


Figure 11-5. Wiring Diagram for XMT 350 MPa (208 - 575 Volt) Eff. w/LJ410832A Thru MB380678A (1 of 2)


231 458-A


Figure 11-6. Wiring Diagram for XMT 350 MPa (208 − 575 Volt) Eff. w/LJ410832A Thru MB380678A (2 of 2)


231 458-A


Figure 11-7. Wiring Diagram for XMT 350 MPa (208 - 575 Volt) Eff. w/MB380679A And Following (1 of 2)


256 241-A


Figure 11-8. Wiring Diagram for XMT 350 MPa (208 − 575 Volt) Eff. w/MB380679A And Following (2 of 2)


256 241-A


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!

XMT 350 MPaAuto-Line

Eff w/LJ410832A And FollowingFor OM-231 242 Revisions C Thru L

TM-231 242G 2012−01

Eff w/Serial Number LJ410832A

Arc Welding Power Source

Processes

Description

Multiprocess Welding

Visit our website at

www.MillerWelds.com

™

�


SECTION 12 − PARTS LIST FOR LJ410832A AND FOLLOWING

MO

D 2

Ref. 804 771-D

12

3

4

5

11

12

10

9

14

15

1819

2021

22

23

6

24

25

26

27

28

2930

3132

33

34 35

36

3738

39

42 43

45

47

46

4948

50

51

52

55 54

53

56

5758

61

6263

7776

74

65

73

72

6667

68

13

44

75

69

417

8

48

64

MO

D 1

40

20

16

17

59

78

7071

60

64

79

Figure 12-1. Parts Assembly

Eff w/LJ410832A AND FOLLOWING


DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 12-1. Parts Assembly

Quantity

1 216 034 Wrapper (Includes Insulators and Safety Labels) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175 256 Insulator, Side Rh (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 551 Insulator, Side (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 134 327 Label, Warning General Precautionary Static & Wire Feed 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 138 442 Label, Caution Falling Equip Can Cause Injury 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 195 585 Handle, Rubberized Carrying 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 135 483 Label, Important Remove These Two Handle Screws 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 225 097 Heat Sink, Lh Rect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 211 503 Insulator, Heat Sink 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 +212 207 Windtunnel, Lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 196 355 Insulator, Screw 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 199 840 Bus Bar, Diode 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 R3/C4 196 518 Resistor/Capacitor (Prior to MA020694A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 R3/C4 233 052 Resistor/Capacitor (Eff w/MA020694A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 SR1 201 530 Kit, Diode Fast Recovery Bridge 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 D1,D2 201 531 Kit, Diode Power Module 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 RT1 199 798 Thermistor, NTC 30K Ohm @ 25 Deg C 18In Lead 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 CR1 198 549 Relay, Encl 24VDC Spst 35A/300VAC 4Pin Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .16 227 127 Label, Warning Electric Shock/Exploding Parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 227 746 Gasket, Inductor Mounting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 010 546 Bushing, Snap-In Nyl .375 Id X .500 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 L4 218 020 Inductor, Boost 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 179 276 Bushing, Snap-In Nyl 1.000 Id X 1.375 Mtg Hole Cent 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 170 647 Bushing, Snap-In Nyl 1.312 Id X 1.500 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 L3 212 150 Inductor, Output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 T1 212 132 XFMR, HF Litz/Litz W/Boost 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 L1 212 091 Inductor, Input 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 083 147 Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 PC1 224 098 Circuit Card Assy, Control W/Program (Prior to MA070470A) 1. . . . . . . . . . . . . . . . . . . . . . .26 PC1 242 812 Circuit Card Assy, Control W/Program (Eff w/MA070470A) 1. . . . . . . . . . . . . . . . . . . . . . . . .26 PC1 ♦224 649 Circuit Card Assy, Control/Aux Power W/Program (Prior to MA070470A)1. . . . . . . . . . . . .26 PC1 ♦242 341 Circuit Card Assy, Control/Aux Power W/Program (Eff w/MA070470A) 1. . . . . . . . . . . . .

216 113 Stand-Off Support, PC Card .187 Dia W/P&l .375 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG1 115 091 Housing Plug+Pins (Service Kit) RC1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG2 201 665 Housing Plug+Pins (Service Kit) RC2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG3 131 056 Housing Plug+Pins (Service Kit) RC3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG5 131 204 Housing Plug+Pins (Service Kit) RC5 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG7 131 054 Housing Plug+Pins (Service Kit) RC7 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG8 131 054 Housing Plug+Pins (Service Kit) RC8 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG9 115 093 Housing Plug+Pins (Service Kit) RC9 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 115 094 Housing Plug+Pins (Service Kit) RC10 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG11 115 094 Housing Plug+Pins (Service Kit) RC11 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG12 115 092 Housing Plug+Pins (Service Kit) RC12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 212 072 Bracket, Mtg Capacitor/PC Board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 C12,13 219 930 Kit, Capacitor Elctlt Replacement 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC2 ♦604 176 Rcpt, Str Dx Grd 2P3W 15A 125V *5−15R 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 CB2 083 432 Supplementary Protector, Man Reset 1P 10A 250VAC Frict 1. . . . . . . . . . . . . . . . . . . . . . . . .30 CB1 089 807 Supplementary Protector, Man Reset 1P 2.5A 250VAC Frict 1. . . . . . . . . . . . . . . . . . . . . . . .30 CB1 ♦083 432 Supplementary Protector, Man Reset 1P 10A 250VAC Frict 1. . . . . . . . . . . . . . . . . . . . . . .31 +212 071 Panel, Rear Standard 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 ♦+212 202 Panel, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 126 026 Label, Warning Electric Shock Can Kill Significant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.♦Part of 115V Aux Power Option.♦♦Part of Tweco Type Connector OptionBE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.



DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 12-1. Parts Assembly (Continued)

Quantity

33 Nameplate, Rear (Order by Model and Serial Number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 ♦ Nameplate, Rear Aux (Order by Model and Serial Number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦217 297 Cover, Receptacle Weatherproof Duplex Rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 217 480 Label, Warning Incorrect Connections 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 215 980 Bushing, Strain Relief .709/.984 Id X1.375 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 219 487 Cable, Power 12 Ft 8Ga 4C (Non-Stripped End) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 234 126 Nut, Conduit 1.000 Npt Knurled 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 T2 211 109 XFMR, Control 665V 336Va Syn Aux Pwr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 T2 ♦211 968 XFMR, Control Toroidal 665 VAC Pri 1536 VA 60 Hz . . . . . . . . . . . . . . .

(Prior to MB520506A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 T2 ♦251 003 XFMR, Control Toroidal 665 VAC Pri 1536 VA 60 Hz . . . . . . . . . . . . . . .

(Eff w/MB520506A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .♦212 947 Plate, Mtg Toroid XFMR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 L2 218 018 Inductor, Pre-Regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 218 566 Gasket, Inductor Mounting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 CT1 196 231 XMFR, Current Sensing 200/1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 C15 196 143 Capacitor, Polyp Met Film 16. Uf 400 VAC 10% 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 216 117 Bracket, Mtg Capacitor Series 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 RT2 199 798 Thermistor, Ntc 30K Ohm @ 25 Deg C 18in Lead 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 PC2 225 442 Circuit Card Assy, Interconnect W/Label & Clips (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . .46 126 026 Label, Warning Electric Shock Can Kill Significant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

223 343 Clip, Wire Stdf .40−.50 Bndl .156Hole .031−.078Thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 153 403 Bushing, Snap-In Nyl .750 Id X 1.000 Mtg Hole Cent 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 217 625 Kit, Input/Pre-Regulator And Inverter Module (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOD 1, SKiip 83 HEC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MOD 2, SKiip 83 EC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG13 130 203 Housing Plug+Pins (Service Kit) RC1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG14 201 665 Housing Plug+Pins (Service Kit) RC2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG15 115 092 Housing Plug+Pins (Service Kit) RC3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG20 115 093 Housing Plug+Pins (Service Kit) RC6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 RM1 205 751 Module, Power Resistor W/Plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 212 206 Windtunnel, Rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 196 330 Heat Sink, Power Module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 +175 132 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 153 178 Label, Warning Exploding Parts Can Serious Injury 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 176 736 Screw, Mtg Foot 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 173 693 Foot, Mtg Unit (Prior to MA020694A) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 229 325 Foot, Mtg Unit (Eff w/MA020694A) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 212 074 Bus Bar, Output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 HD1 182 918 Transducer, Current 400A Module Supply V +/− 15V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 PC3 225 680 Circuit Card Assy, Front Panel & Display W/Program . . . . . . . . . . . . . . .

(Prior to LJ410832A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 PC3 240 631 Circuit Card Assy, Front Panel & Display W/Program . . . . . . . . . . . . . . .

(Eff w/LJ410832A thru MA060330P) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 PC3 242 725 Circuit Card Assy, Front Panel & Display W/Program . . . . . . . . . . . . . . .

(Eff w/MA060331P) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PLG18 131 204 Housing Plug+Pins (Service Kit) RC2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RC50 210 233 Rcpt, W/Pins (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG21 212 088 Plug, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RC21 167 640 Housing Plug+Pins (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 230 943 Enclosure, Connector DB−9 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 230 944 Cover, Enclosure Connector DB−9 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 S1 231 191 Switch, Tgl 3Pst 50A 600VAC Scr Term Wide Tgl (Prior to MA430012A) 1. . . . . . . . . . . . . . . .61 S1 244 920 Switch, Tgl 3Pst 40A 600VAC Scr Term Wide Tgl (Eff w/MA430012A) 1. . . . . . . . . . . . . . . . .




DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 12-1. Parts Assembly (Continued)

Quantity

62 176 226 Insulator, Switch Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 FM1 196 313 Fan, Muffin 115V 50/60Hz 3000 RPM 6.378 Mtg Holes 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG16 131 054 Housing Plug+Pins (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RC16 135 635 Housing Plug+Pins (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 208 967 Rcpt Assy, Tw Lk Insul Fem (Dinse Type) 50/70 Series (Includes) 2. . . . . . . . . . . . . . . . . . . . . . . .208 968 Rcpt, Tw Lk Insul W/O-Ring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 712 Insulator, Bulkhead Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 713 Insulator, Bulkhead Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 714 Washer, Tooth 22Mmid X 31.5Mmod 1.310-1Mmt Intern 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 717 Nut, M20-1.5 1.00Hex .19H Brs Locking 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 718 O-Ring, 0.989 Id X 0.070 H 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186 228 O-Ring, 0.739 Id X 0.070 H 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 548 Terminal, Connection Friction (Eff w/MB520506A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 ♦♦218 183 Rcpt Assy, Tw Lk Insul Fem(Tweco Type) (Fac−Op) (Includes) 2. . . . . . . . . . . . . . . . . . . . . . . .209 473 Rcpt, Twist Lock Tweco Style (Female) Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 712 Insulator, Bulkhead Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 713 Insulator, Bulkhead Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 714 Washer, Tooth 22Mmid X 31.5Mmod 1.310-1Mmt Intern 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 717 Nut, M20-1.5 1.00Hex .19H Brs Locking 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 718 O-Ring, 0.989 Id X 0.070 H 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186 228 O-Ring, 0.739 Id X 0.070 H 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 548 Terminal, Connection Friction (Eff w/MB520506A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 Nameplate, Power (Order by Model and Serial Number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 231 473 Label, Process (Prior to LJ410832A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 240 959 Label, Process (Eff w/LJ410832A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 218 041 Door, W/Quick Access Ball Fasteners 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 175 138 Box, Louver 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Label, (Order by Model and Serial Number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 174 991 Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip−.21 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 231 468 Nut, 375−32 .56Hex .22H Brs Conical Knurl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 231 469 Nut, 500−28 .69Hex .28H Brs Conical Knurl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Nameplate, Connection (Order by Model and Serial Number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Nameplate (Order by Model and Serial Number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 216 112 Fastener, Panel Receptacle Quick Access 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 C6,7 214 749 Capacitor Assy, W/Plug And Leads (Voltage Feedback) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .77 226 590 Panel, Front Standard 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 231 470 Nut, Adapter Encoder Shaft Mtg 375−32 To 500−28 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 L8 241 027 Core, Toroidal (Eff w/MB380679A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2012 Miller Electric Mfg. Co.

Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA

International Headquarters−USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125

For International Locations Visitwww.MillerWelds.com

xmt350mpaauto line (lj410832a)

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