TM-231 242G Processes

Multiprocess Welding

201201

Eff w/Serial Number LJ410832A

Description

Arc Welding Power Source

Effective with Serial No. LJ410832A

R

XMT 350 MPa Auto-Line

File: MULTIPROCESS
Visit our website at

www.MillerWelds.com

INFORMATION ON OLDER UNITS

. This manual includes operating information for current units. To obtain specific operating information for older models, download the applicable Owners 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. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Features And Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Arc Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Weld Output Receptacles And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Optional 115 Volts AC Duplex Receptacle And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . 3-7. Optional Gas Valve Operation And Shielding Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Mode Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Configuration Option Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 GTAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Typical Connection For GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Scratch Start TIG Welding Mode - GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Lift-Arc TIG Welding Mode - GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. TIG Welding Mode - GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 GMAW/GMAW-P/FCAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Typical Connection For Remote Control Feeder GMAW/GMAW-P/FCAW Process . . . . . . . . . . . . . . 6-2. MIG Welding Mode - GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. MIG - Wire and Gas Selection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Pulsed MIG Welding Mode - GMAW-P Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5. Pulsed MIG - Wire and Gas Selection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6. Remote Process Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7. Typical Connection For Voltage-Sensing Feeder GMAW/GMAW-P/FCAW Process . . . . . . . . . . . . . . 6-8. V-Sense Feeder Welding Mode - GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9. V-Sense Feeder Welding Mode - GMAW-P Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 SMAW/CAC-A OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Typical Connection For SMAW And CAC-A Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. CC Welding Mode - SMAW/CAC-A Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Stick Welding Mode - SMAW/CAC-A Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Optional Low Open Circuit Voltage (OCV) Welding Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Checking Unit Before Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 2 2 3 3 3 3 4 5 5 5 5 6 7 7 8 9 10 11 12 12 13 14 16 16 17 18 19 20 20 21 22 23 24 25 26 27 28 29 29 30 31 32 34 37 37 38

TABLE OF CONTENTS
SECTION 9 TROUBLESHOOTING (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3. Input Pre-Regulator Module (MOD1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4. Input Pre-Regulator Module (MOD1) Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5. Inverter Module (MOD2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6. Inverter Module (MOD2) Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7. Power Interconnect Board PC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8. Power Interconnect Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9. Control Board PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10. Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11. Power Switch (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12. Output Diodes D1, D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13. Output Diodes D1, D2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14. Stick Boost Rectifier (SR1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15. Stick Boost Rectifier (SR1) Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17. Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18. Troubleshooting Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19. Control Board PC1 Testing Information (Use with Section 9-20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20. Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21. Control Board PC1 Power Off Checks (Prior To MA070470A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22. Control Board PC1 Power Off Checks (Prior To MA070470A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23. Control Board PC1 - Power Off Checks (Effective With MA070470A) . . . . . . . . . . . . . . . . . . . . . . . . . 9-24. Control Board PC1 Power Off Checks (Effective With MA070470A) . . . . . . . . . . . . . . . . . . . . . . . . . 9-25. Power Interconnect Board PC2 Testing Information (Use with Section 9-26) . . . . . . . . . . . . . . . . . . . . 9-26. Power Interconnect Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27. Power Interconnect Board (PC2) - Power Off Checks (Prior To MB510232A) . . . . . . . . . . . . . . . . . . . 9-28. Power Interconnect Board (PC2) - Power Off Checks (Prior To MB510232A) . . . . . . . . . . . . . . . . . . . 9-29. Power Interconnect Board (PC2) - Power Off Checks (Effective With MB510232A) . . . . . . . . . . . . . . 9-30. Power Interconnect Board (PC2) - Power Off Checks (Effective With MB510232A) . . . . . . . . . . . . . . 9-31. Front Panel/Display Board PC3 Testing Information (Use with Section 9-32) . . . . . . . . . . . . . . . . . . . . 9-32. Front Panel/Display Board PC3 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34. Enabling Low Open Circuit Voltage Welding Modes (Optional) Effective W/MA100311A . . . . . . . . . . SECTION 10 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3. Removing Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 12 PARTS LIST FOR LJ410832A AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 39 39 40 40 41 41 42 42 43 44 44 45 45 46 48 50 52 53 56 57 58 59 60 61 64 65 66 67 68 69 70 71 72 72 72 73 75 94

SECTION 1 SAFETY PRECAUTIONS FOR SERVICING

Protect yourself and others from injury read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

OM-231 242-L, safety_stm 201110

DANGER! Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. NOTICE Indicates statements not related to personal injury.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

1-2. Servicing Hazards

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. Only qualified persons should test, maintain, and repair this unit. During servicing, keep everybody, especially children, away.

FLYING METAL or DIRT can injure eyes.

D Wear safety glasses with side shields or face shield during servicing. D Be careful not to short metal tools, parts, or wires together during testing and servicing.

HOT PARTS can burn. ELECTRIC SHOCK can kill.

D Do not touch live electrical parts. D Turn Off welding power source and wire feeder and disconnect and lockout input power using line disconnect switch, circuit breakers, or by removing plug from receptacle, or stop engine before servicing unless the procedure specifically requires an energized unit. D D D D D Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground. Do not leave live unit unattended. If this procedure requires an energized unit, have only personnel familiar with and following standard safety practices do the job. When testing a live unit, use the one-hand method. Do not put both hands inside unit. Keep one hand free. Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source. D Do not touch hot parts bare handed. D Allow cooling period before working on equipment. D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

EXPLODING PARTS can injure.

D Failed parts can explode or cause other parts to explode when power is applied to inverters. D Always wear a face shield and long sleeves when servicing inverters.

SHOCK HAZARD from testing.

D Turn Off welding power source and wire feeder or stop engine before making or changing meter lead connections. D Use at least one meter lead that has a selfretaining spring clip such as an alligator clip. D Read instructions for test equipment.

SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Troubleshooting Section before touching any parts.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling boards or parts. D Use proper static-proof bags and boxes to store, move, or ship PC boards.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. D Use equipment of adequate capacity to lift and support unit. D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. D Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94110) when manually lifting heavy parts or equipment. TM-231 242 Page 1

FIRE OR EXPLOSION hazard.

D Do not place unit on, over, or near combustible surfaces. D Do not service unit near flammables. XMT 350 MPa

MOVING PARTS can injure.

D Keep away from moving parts such as fans. D Keep away from pinch points such as drive rolls. D Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. D Keep hands, hair, loose clothing, and tools away from moving parts. D Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment install, test, and service H.F. producing units. D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. D If notified by the FCC about interference, stop using the equipment at once. D Have the installation regularly checked and maintained. D Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted Medical Devices should keep away from servicing areas until consulting their doctor and the device manufacturer.

READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when servicing this unit. D Consult the Owners Manual for welding safety precautions. D Use only genuine replacement parts from the manufacturer. D Read and follow all labels and the Technical Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.

OVERUSE can cause OVERHEATING.

D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before starting to weld again. D Do not block or filter airflow to unit.

1-3. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use.

1-4. EMF Information

Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passersby or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 1. Keep cables close together by twisting or taping them, or using a cable cover. 2. Do not place your body between welding cables. Arrange cables to 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 the welding circuit as possible. 5. Connect work clamp to workpiece as close to the weld as possible. 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 wire feeder. About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

TM-231 242 Page 2

XMT 350 MPa

SECTION 2 INTRODUCTION
2-1. Specifications
Amperage Range in CC Mode 5425 A Max. OpenCircuit Voltage 75 VDC RMS Amps Input at Rated Load Output, 60 Hz 3-Phase at NEMA Load Voltages and Class I Rating 208 V 40.4 230 V 36.1 400 V 20.6 460 V 17.8 575 V 14.1 KVA 14.2 KW 13.6

Input Power 3-Phase

Rated Output 350 A at 34 VDC, 60% Duty Cycle 300 A at 32 VDC, 60% Duty Cycle*

Voltage Range in CV Mode 1038 V

1-Phase

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-Linet Power Management Technology is circuitry that automatically adapts the power source to the primary voltage being applied (see Sections 3-9 and 3-10). LVCt Line Voltage Compensation is circuitry that keeps the power source output constant regardless of input power fluctuation. Wind Tunnel Technologyt circulates air over components that require cooling, not over electronic circuitry, which reduces contaminants and improves reliability in harsh welding environments. Fan-On-Demandt cooling system operates only when needed, reducing noise, energy use and the amount of contaminants pulled through the machine. Thermal Overload Protection automatically shuts down the unit, only when necessary to prevent damage to internal components 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 the remote control is dependent on the Mode Switch Setting (see Section 4-2). Lift-Arct TIG starts provide a contamination free weld without the use of high frequency in the Lift-Arc TIG Welding Mode (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 in CC 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 (see Sections 7-2 and 7-3). Inductance influences the arc stiffness, bead width and appearance, and puddle fluidity in MIG and V-Sense Feeder Welding Modes (see Sections 6-2 and 6-8). SharpArct optimizes the size and shape of the arc cone, bead width and appearance, and puddle fluidity in Pulsed MIG Welding Mode (see Section 6-4).

XMT 350 MPa

TM-231 242 Page 3

2-4. Duty Cycle And Overheating

Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops, a Help message is displayed and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding.

. Single Phase Operation: The

unit is supplied with a 8 AWG power cord. The rated output with 8 AWG is 300 amps, 32 volts at 40% duty cycle. To achieve 60% duty cycle change cord to 6 AWG.

NOTICE Exceeding duty cycle can damage unit and void warranty.

60% Duty Cycle

6 Minutes Welding Overheating

4 Minutes Resting

A or V
15

Minutes

OR Reduce Duty Cycle

Ref. 216 568-A

TM-231 242 Page 4

XMT 350 MPa

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

3-2. Dimensions And Weight

Hole Layout Dimensions A B C D E F G 11-3/4 in. (298 mm) F 1-11/16 in. (42 mm) 15-3/4 in. (400 mm) 19-3/32 in. (485 mm) 8-11/16 in. (221 mm) D 1-17/32 in. (39 mm) 1/4-20 UNC -2B thread Weight 80 lb (36.3 kg) 93.5 lb (42.4 kg) w/optional 115 VAC 12-1/2 in. (318 mm) B
804 801-A

A E G 24 in. (610 mm)

17 in. (432 mm)

3-3. Selecting a Location

1 2 Movement 1 Lifting Handles Hand Cart Use handles to lift unit. Use cart or similar device to move unit.

Do not move or operate unit where it could tip.

Line Disconnect Device

Locate unit near correct input power supply.

!
2

Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20.

Location

18 in. (460 mm)

18 in. (460 mm)

XMT Location 1

XMT 350 MPa

TM-231 242 Page 5

3-4. Weld Output Receptacles And Selecting Cable Sizes

NOTICE The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 30 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 cable size.

Weld Output Terminals

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding***

Turn off power before connecting to weld output terminals. Do not use worn, damaged, undersized, or poorly spliced cables.

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)

Welding Amperes
100 150 200

10 60% Duty Cycle

AWG (mm2) 4 (20) 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60) 2/0 (70) 3/0 (95)

60 100% Duty Cycle

AWG (mm2) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 2/0 (70) 3/0 (95) 4/0 (120) 4 (20) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 3 (30) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95)

10 100% Duty Cycle

AWG (mm2) 2 (35) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 1 (50) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 1/0 (60) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 1/0 (60) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120)

250 300 350 400

Output Receptacles 500 600

* 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 201107

TM-231 242 Page 6

XMT 350 MPa

3-5. Remote 14 Receptacle Information

Socket* A Socket Information 24 volts AC. Protected by supplementary protector CB2. Contact closure to A completes 24 volts AC contactor control circuit. 115 volts AC. Protected by supplementary protector CB1. Contact closure to I completes 115 volts AC contactor control circuit. Output to remote control; 0 to +10 volts DC, +10 volts DC in MIG mode. Remote control circuit common. 0 to +10 volts DC input command signal from remote control. Wirefeed speed command, 0 to +10 volts DC output signal from wire feeder. CC/CV Select; 0 to +10 volts DC. Wirefeed speed common. Current feedback; +1 volt DC per 100 amperes. Voltage feedback; +1 volt DC per 10 output receptacle volts. Circuit common for 24 and 115 volts AC circuits. Chassis common.

24 VOLTS AC
B

A B

J I

115 VOLTS AC
J

H C L N M D G E F

REMOTE OUTPUT CONTROL

D E

M N

A/V
AMPERAGE VOLTAGE GND
*The remaining sockets are not used.

F H

G K

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

1 115 V 10 Amp AC Receptacle Power is shared between duplex receptacle and Remote 14 receptacle (see Section 3-5). 1 2 3 Supplementary Protector CB1 Supplementary Protector CB2

CB1 protects duplex receptacle and 115 volts AC portion of Remote 14 receptacle from overload. CB2 protects 24 volts AC portion of Remote 14 receptacle from overload. Press button to reset supplementary protector.

803 691-C

XMT 350 MPa

TM-231 242 Page 7

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

Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 2 4 3 Cylinder Regulator/Flowmeter Gas Hose Connection

Install so face is vertical. Fitting has 5/8-18 right-hand threads. Obtain and install gas hose. 2 4 5 Gas In Fitting Gas Out Fitting

GAS IN

The Gas In and Gas Out fittings have 5/8-18 right-hand threads. Obtain proper size, type, and length hose and make connections as follows: Connect hose from shielding gas supply regulator/flowmeter to Gas In fitting. Connect hose coupler to torch. Connect one end of gas hose to hose coupler. Connect remaining end of gas hose to Gas Out fitting. Operation 3 1 The gas solenoid controls gas flow during the TIG process as follows: Remote TIG Gas flow starts with remote contactor on. Gas flow stops at end of postflow if current was detected, or with remote contactor off if no current was detected. LiftArc TIG Gas flow starts when tungsten touches work (touch sensed). Gas flow stops at end of postflow. Scratch Start TIG 5 Gas flow starts when current is detected. Gas flow stops at end of postflow. Postflow time is factory set to 5 seconds per 100 amps of weld current. The minimum postflow time is 5 seconds. The maximum post flow is 20 seconds (post flow settings are not adjustable by the end user).

GAS OUT

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

TM-231 242 Page 8

XMT 350 MPa

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 input voltage 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 recommendations 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 rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12. Single-Phase Input Voltage (V) Input Amperes (A) At Rated Output Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay Fuses 2 Normal Operating Fuses 3 Min Input Conductor Size In AWG4 Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG 4 70 80 8 72 (22) 8 60 80 8 89 (27) 8 35 45 10 176 (54) 10 30 40 12 140 (43) 12 25 30 12 219 (67) 12 208 60.8 230 54.6 400 29.7 460 25.4 575 19.9

Three-Phase Input Voltage (V) Input Amperes (A) At Rated Output Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay Fuses 2 Normal Operating Fuses 3 Min Input Conductor Size In AWG4 Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG 4 1 2 3 4 45 60 8 119 (36) 10 40 50 10 96 (29) 10 25 30 12 175 (53) 12 20 25 14 150 (46) 14 15 20 14 234 (71) 14 208 40.4 230 36.1 400 20.6 460 17.8 575 14.1

Reference: 2011 National Electrical Code (NEC) (including article 630) If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. Time-Delay fuses are UL class RK5. See UL 248. 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). 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 cable requirements.

XMT 350 MPa

TM-231 242 Page 9

3-9. Connecting 1-Phase Input Power

!
Installation must meet all National and Local Codes have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors from unit. Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal. automatically adapts the power source to the primary voltage being applied. Check input voltage available at site. This unit can be connected to any input power between 208 and 575 VAC without removing cover to relink the power source.

1
!
8 =GND/PE Earth Ground 10

. The Auto-Line circuitry in this unit

See rating label on unit and check input voltage available at site. L1 L2 3 1 1 1 2 3 4 5 2 6 3 Black And White Input Conductor (L1 And L2) Red Input Conductor Green Or Green/Yellow Grounding Conductor Insulation Sleeving Electrical Tape

6 5 4

Insulate and isolate red conductor as shown. 6 Input Power Cord. 7 Disconnect Device (switch shown in the OFF position) 8 Disconnect Device Grounding Terminal 9 Disconnect Device Line Terminals Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. Connect input conductors L1 and L2 to disconnect device line terminals. 10 Overcurrent Protection Select type and size of overcurrent protection using Section 3-8 (fused disconnect switch shown). Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.

Tools Needed:
input1 201103 803 766-C

TM-231 242 Page 10

XMT 350 MPa

3-10. Connecting 3-Phase Input Power

! !
Installation must meet all National and Local Codes have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors from unit. Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. tomatically adapts the power source to the primary voltage being applied. Check input voltage available at site. This unit can be connected to any input power between 208 and 575 VAC without removing cover to relink the power source.

3
!
= GND/PE Earth Ground 4

. The Auto-Line circuitry in this unit au7

See rating label on unit and check input voltage available at site. For Three-Phase Operation 1 2 Input Power Cord. Disconnect Device (switch shown in the OFF position) Green Or Green/Yellow Grounding Conductor Disconnect Device Grounding Terminal Input Conductors (L1, L2 And L3) Disconnect Device Line Terminals

L1 3 6 L2 L3 5 3 4 5 6

Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. Connect input conductors L1, L2, and L3 to disconnect device line terminals. 7 Overcurrent Protection Select type and size of overcurrent protection using Section 3-8 (fused disconnect switch shown). Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.

Tools Needed:

input1 201103 803 766-C

XMT 350 MPa

TM-231 242 Page 11

SECTION 4 GENERAL OPERATION

4-1. Front Panel

8 10 11

12

13 14

15

19

18

16 17
804 772-A / 226 611-A

. Weld
1 2 3 4 5 6

process operation sections describe functionality of the identified items.

. The meters display the actual weld output

values after arc initiation and remains displayed for approximately three seconds after the arc is broken. 7 Amps Indicator 8 Setup Indicator 9 Adjust Control 10 Wire Type Indicator 11 Arc Control Indicator

Remote 14 Receptacle Output ON Indicator Light Volts Indicator Left Display Arc Length Indicator Right Display

12 13 14 15 16 17 18 19

Remote PC Interface Setup Button Gas Type Indicator Mode Switch Power Switch Weld Output Terminal () Optional Gas Valve Knockout Weld Output Terminal (+)

TM-231 242 Page 12

XMT 350 MPa

4-2. Mode Switch Settings

Switch Position Scratch Start TIG Process GTAW Output Control Electrode Hot Panel Adjust Amps Remote Adjust % Panel Amps*

Lift-Arc TIG

GTAW

Electrode Hot

Amps

% Panel Amps*

TIG

GTAW

Remote 14

Amps

% Panel Amps

MIG Pulsed MIG

GMAW GMAW-P SMAW CAC-A SMAW CAC-A GMAW*

Remote 14 Remote 14

Volts Arc Length (0100)*

Volts Arc Length (0100)*

CC

Remote 14

Amps

% Panel Amps

Stick

Electrode Hot

Amps

% Panel Amps*

V-Sense Feeder

Electrode Hot

Volts

Volts

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

Notes

XMT 350 MPa

TM-231 242 Page 13

4-3. Configuration Option Menu

SET

-UP

226 611-A

2 1 2 3 4 5 6 7 Mode Switch Remote 14 Receptacle Left Display Right Display Adjustment Control Remote PC Interface Setup Button Setup

1 Right Displays. SETUP will be displayed momentarily. Configuration options are displayed in the Left Display. Settings are displayed in the Right Display. Settings can be changed by turning the Adjust Control. If a setting does not change when the Adjust Control is turned, the option is not configurable. Pressing the Setup Button moves to the next configuration option.

The Configuration Option Menu provides a means to customize some machine features for desired operation. To enter the Configuration Option Menu, hold the Setup Button down during power up while the unit is displaying 8888 on the Left and

TM-231 242 Page 14

XMT 350 MPa

4-3

Configuration Option Menu (Continued)

V.SEN PULS

MIG AUTO

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 VSENSE FEEDER position. See Section 6-2 for MIG operation or Section 6-4 for Pulsed MIG operation. Pulsed MIG Manual/Auto Control This option sets the PULSED MIG control as manual (PULS MAN) or Auto (PULS AUTO) operation. When set to manual operation, the arc length setting on power source and wire speed setting on wirefeeder need to be adjusted independently to achieve the desired arc length. When set to Auto operation, once arc length is determined it is not necessary to change the arc length value with changes in wirefeed speed. The XMT 350 MPa and synergic feeders allow 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.

. 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 manual when any other feeder is connected. See product literature for a list of compatible synergic feeders.

PULS WFS VRD

ARC.L IPM OFF

Pulsed MIG Adjustment This option allows adjusting the Pulsed MIG process in units of Arc Length (PULS ARC.L) or preset voltage (PULS VOLT). Wire Feed Speed And Wire Diameter Units WFS IPM: WFS is displayed in inches per minute Diameter is displayed in inches WFS MPM: WFS is displayed in meters per minute Diameter is displayed in millimeters Voltage Reducing Device (VRD) Mode This option enables (ON) or disables (OFF) low open circuit voltage (OCV) operation in Stick and Scratch Start TIG modes. See Section 7-4 for Low OCV Operation. When enabled, VRD ON is momentarily displayed after the power-on front panel LED test.

. If VRD -ON is displayed with a dash preceding ON, Low

OCV Operation is enabled by hardware configuration and cannot be disabled in this menu.

Panel and Remote Adjustment

PANL

RMT

When the Mode Switch is set to SCRATCH START TIG, LIFTARC TIG, or STICK, the remote command behavior is configurable. SCRATCH START TIG and LIFTARC TIG default to panel and remote (PANL RMT) amperage adjustment but can be configured for panel only (PANL ONLY) adjustment. The default amperage adjustment for STICK is panel only (PANL ONLY) but can also be configured for panel and remote (PANL RMT) adjustment. All other Mode Switch positions are nonconfigurable and allow both panel and remote (PANL RMT) adjustment.

. Panel adjustment is made using the Adjust Control on

the front panel. Remote adjustment is made using a remote control device connected to the Remote 14 Receptacle.

XMT 350 MPa

TM-231 242 Page 15

4-3

Configuration Option Menu (Continued)

INFO

NO

Revision Information This option identifies the units weld library (INFO LIB) and firmware revision (INFO REV). Press the Setup Button while the unit is displaying INFO LIB to identify the units weld library. Press the Setup Button while the unit is displaying INFO REV to identify the units firmware revision. Pressing the Setup Button while the unit is displaying INFO NO will move to the next configuration option. Exit Configuration Option Menu Press the Setup Button while the unit is displaying EXIT NO to return to the first configuration option. Press the Setup Button while the unit is displaying EXIT YES to exit the Configuration Option Menu.

EXIT

NO

. The Configuration Option Menu can be ex-

ited at any time by turning the unit off. Only if the unit is turned off after EXIT NO is displayed will configuration option changes be saved.

SECTION 5 GTAW OPERATION

5-1. Typical Connection For GTAW Process
!
1 2 6 3 4 5 Turn off power before making connections. Foot Control Gas Out Connection (Optional) Positive (+) Weld Output Terminal Remote 14 Receptacle

Connect desired remote control to Remote 14 receptacle if required. 5 6 7 Gas In Connection (Optional) Gas Cylinder Negative () Weld Output Terminal TIG Torch Workpiece

4 1 3 2

8 9

804 841-B

TM-231 242 Page 16

XMT 350 MPa

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

7 2. 0

85

226 611-A

Weld terminals are energized at all times in Scratch Start TIG welding mode. Mode Switch Volts Indicator Left Display Right Display Amps Indicator Adjust Control

Setup For typical system connections refer to Section 5-1. Rotate Mode Switch to SCRATCH START TIG position as shown. The open circuit voltage is shown in the Left Display with the Volts Indicator lit. Preset amperage is shown in the Right Display with the Amps Indicator lit.

Operation The Adjust Control is used to set desired preset amperage.

1 2 3 4 5 6

. If a remote control is used for amper. For

age adjustment, the adjustment will function as a percentage of the preset amperage. best results, gently scratch the tungsten electrode to the work to initiate an arc. To minimize arc flare at the end of the weld, pull back the electrode quickly to extinguish the arc.

XMT 350 MPa

TM-231 242 Page 17

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

1 3. 5

85

226 611-A

Touch 7

12 Seconds

Do NOT Strike Like A Match!

!
1 2 3 4 5 6 7 8

Weld terminals are energized at all times in Lift Arc TIG welding mode. Mode Switch Volts Indicator Left Display Right Display Amps Indicator Adjust Control Workpiece Tungsten Electrode

Setup For typical system connections refer to Section 5-1. Rotate Mode Switch to LIFT-ARC TIG position as shown. The open-circuit voltage is shown in the Left Display with the Volts Indicator lit. Preset amperage is shown in the Right Display with the Amps Indicator lit. Normal open-circuit voltage is not present before the electrode touches the workpiece, instead a low sensing voltage is present. The sensing voltage allows the electrode to touch the workpiece without overheating, sticking, or getting contaminated.

Operation The Adjust Control is used to set desired preset amperage.

. If a remote control is used for amper-

age adjustment, the adjustment will function as a percentage of the preset amperage.

. For best results, firmly touch the tung-

sten electrode to the workpiece at the weld start point. Hold electrode to workpiece for 1-2 seconds, and lift electrode. An arc will form when the electrode is lifted. To minimize arc flare at the end of the weld, pull back the electrode quickly to extinguish the arc.

TM-231 242 Page 18

XMT 350 MPa

5-4. TIG Welding Mode - GTAW Process

85 8

226 611-A

!
1 2 3 4 5

Weld terminals are energized through the remote control in TIG welding mode. Mode Switch Left Display Right Display Amps Indicator Adjust Control

Setup For typical system connections refer to Section 5-1. Rotate Mode Switch to TIG position as shown. The preset amperage is shown in the Right Display with the Amps Indicator lit.

Operation The Adjust Control is used to set desired preset amperage. A remote control is required to turn on the weld output.

. If the remote control has an amperage

adjustment, the adjustment will function as a percentage of the preset amperage.

. For

best results, gently scratch the tungsten electrode to the work to initiate an arc. To minimize arc flare at the end of the weld, pull back the electrode quickly to extinguish the arc.

XMT 350 MPa

TM-231 242 Page 19

SECTION 6 GMAW/GMAW-P/FCAW OPERATION

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

9 1 2 3

8 7

6
804 938-A

!
1 2 3 4

Turn off power before making connections. Remote 14-Receptacle Positive (+) Weld Output Terminal Negative () Weld Output Terminal Ground Cable to Workpiece

5 6 7 8 9

Workpiece Gun Wire Feeder Gas Hose Gas Cylinder

Use of shielding gas is dependant on Wire Type.

. The

connection diagram illustrates DCEP (reverse polarity) suitable for all wires except self-shielded FCAW. The majority of self-shielded FCAW wires require DCEN (straight polarity).

TM-231 242 Page 20

XMT 350 MPa

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

2 5. 0
6 7

8 9
226 611-A

!
1 2 3 4 5 6 7 8 9

Weld terminals are energized through the remote control in MIG welding mode. Mode Switch Volts Indicator Left Display Right Display Adjust Control Wire Type Indicator Arc Control Indicator Setup Button Gas Type Indicator

. The preset voltage can be adjusted re-

motely at the wire feeder if the feeder has a voltage control. This voltage control will override the Adjust Control of preset voltage on the welding power source.

Press the Setup Button to confirm the selection. The unit will acknowledge a change of wire and gas information by displaying PROG LOAD momentarily. Arc Control (Inductance) Press the Setup Button repeatedly until the Arc Control indicator is lit. INDU appears on the Left Display, and the corresponding inductance setting appears on the Right Display. Rotate Adjust Control to select desired inductance setting from 0 to 100. Use lower inductance settings to stiffen the arc and reduce puddle fluidity. Use higher inductance settings to soften the arc and increase puddle fluidity. Refer to the MIG Wire and Gas Selection Table (see Section 6-3) for suggested inductance setting for the specific wire and gas being used. Press the Setup Button to return to adjustment of preset voltage.

Pressing the Setup Button allows adjustment of Arc Control, Wire Type, Gas Type and preset voltage.

. For best results, select the appropriate

Setup For typical system connections refer to Section 6-1. Rotate Mode Switch to MIG position as shown. The preset voltage is shown in the Left Display with the Volts Indicator lit. Operation While the Volts Indicator is lit under the Left Display, the Adjust Control is used to set desired preset voltage.

Wire and Gas Type to match the actual wire and gas being used. Refer to the MIG Wire and Gas Selection Table for available wires and gases (see Section 6-3).

Selecting a Wire and Gas Press the Setup Button repeatedly until the Wire Type indicator is lit. The active Wire Type will appear in the Left and Right Display. Rotate Adjust Control to select desired wire. Press the Setup Button again so the Gas Type indicator is lit. The active Gas Type will appear in the Left and Right Display. Rotate Adjust Control to select desired gas.

. Each Wire and Gas Type combination

has independent preset voltage and inductance settings. These settings are preserved when the unit is turned off.

XMT 350 MPa

TM-231 242 Page 21

6-3. MIG - Wire and Gas Selection Table

WIRE TYPES**
.035 (0.9) STL .045 (1.2) STL .052 (1.4) STL .035 (0.9) STL .045 (1.2) STL .035 (0.9) FCAW .045 (1.2) FCAW .052 (1.4) FCAW 1/16 (1.6) FCAW .045 (1.2) MCOR .052 (1.4) MCOR 1/16 (1.6) MCOR .035 (0.9) SSTL .045 (1.2) SSTL .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) Aluminum .035 (0.9) AL5X (5000 Series) .040 (1.0) AL5X (5000 Series) 3/64 (1.2) AL5X (5000 Series) 1/16 (1.6) AL5X (5000 Series) *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. ARGN (ARGON) 10

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

DEFAULT INDUCTANCE
30

Steel

10

Flux Core

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

30 *

Metal Core

ARGN CO2 (ARGON / CARBON DIOXIDE) TRI MIX (TRI-GAS MIXTURE) ARGN OXY (ARGON / OXYGEN)

30

Stainless Steel

70

Notes

TM-231 242 Page 22

XMT 350 MPa

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

25.0
7 8

9 10
226 611-A

!
1 2 3 4 5 6 7 8 9 10

Weld terminals are energized through the remote control in Pulsed MIG welding mode. Mode Switch Volts Indicator Left Display Right Display Arc Length Indicator Adjust Control Wire Type Indicator Arc Control Indicator Setup Button Gas Type Indicator

Pulsed MIG Wire and Gas Selection Table for available wires and gases (see Section 6-5). Selecting a Wire and Gas Press the Setup Button repeatedly until the Wire Type indicator is lit. The active Wire Type will appear in the Left and Right Display. Rotate Adjust Control to select desired wire. Press the Setup Button again so the Gas Type indicator is lit. The active Gas Type will appear in the Left and Right Display. Rotate Adjust Control to select desired gas. Press the Setup Button again to confirm the selection. The unit will acknowledge a change of wire and gas information by displaying PROG LOAD momentarily. Arc Control (SharpArc) Press the Setup Button repeatedly until the Arc Control indicator is lit. SHRP appears on the Left Display, and the corresponding SharpArc setting appears on the Right Display. Rotate Adjust Control to select desired SharpArc setting from 0 to 50, default is 25. Adjusting the SharpArc setting changes the welding arc cone. Lower settings widen the arc cone, increases puddle fluidity and flattens the weld bead appearance. Higher settings narrow the arc cone, reduces puddle fluidity and crowns the weld bead appearance.

Arc Length - Pulsed MIG Manual Control (see Section 4-3) Arc length corresponds to the level of energy needed to burn off the welding electrode. As wire feed speed increases, a higher arc length setting is required to burn off the additional wire. The arc length setting appears in the Left Display when the Arc Length Indicator is lit. Arc length can be adjusted from 0 to 100. After the welding output terminals are energized, but prior to arc initiation, the unit displays the letter R and a reference wire speed (IPM) on the Right Display. The reference wire speed can be used as a starting point for the wire speed setting at the feeder. The wire speed and arc length setting can then be further adjusted to achieve the desired arc length. The Configuration Option Menu (see Section 4-1) can be used to change the arc length setting (0 to 100) to average arc voltage. Average arc voltage can be used as an alternative method to set the Pulsed MIG welding arc with the same parameters (voltage and wire speed) as a conventional MIG arc. Lower voltage settings correspond to tighter arc lengths while higher voltage settings correspond to longer arc lengths. If the voltage mode is selected, the average voltage preset will be displayed on the Left Display with the Volts Indicator lit. Arc Length - Pulsed MIG Auto Control (see Section 4-3) In Auto operation the arc length setting is 0-100. The programs have been developed at 50 arc length setting. Increasing or decreasing the arc length setting from 50 will change the arc length. It is not necessary to change the arc length value when changing wire feed speed settings.

Setup For typical system connections refer to Section 6-1. Rotate Mode Switch to PULSED MIG position as shown. The arc length setting is shown in the Left Display with the Arc Length Indicator lit. Operation While the Arc Length Indicator is lit under the Left Display, the Adjust Control is used to set desired arc length setting.

. The arc length can be adjusted remote-

ly at the wire feeder if the feeder has a voltage control. This voltage control will override the Adjust Control on the welding power source.

Pressing the Setup Button allows adjustment of Arc Control, Wire Type, Gas Type and Arc Length.

. For best results, select the appropriate

. Each Wire and Gas Type combination

has independent Arc Length and SharpArc settings. These settings are preserved when the unit is turned off.

Wire and Gas Type to match the actual wire and gas being used. Refer to

XMT 350 MPa

TM-231 242 Page 23

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

WIRE TYPES*
Steel Metal Core .035 (0.9) STL .045 (1.2) STL .045 (1.2) MCOR .052 (1.4) MCOR .035 (0.9) SSTL .045 (1.2) SSTL .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) Aluminum .035 (0.9) AL5X (5000 Series) .040 (1.0) AL5X (5000 Series) 3/64 (1.2) AL5X (5000 Series) 1/16 (1.6) AL5X (5000 Series) .035 (0.9) NI .045 (1.2) NI .035 (0.9) CUNI .045 (1.2) CUNI .035 (0.9) SIBR .045 (1.2) SIBR

GAS TYPES
ARGN CO2 (ARGON / CARBON DIOXIDE) ARGN OXY (ARGON / OXYGEN) ARGN CO2 (ARGON / CARBON DIOXIDE) TRI MIX (TRI-GAS MIXTURE) ARGN OXY (ARGON / OXYGEN) ARGN CO2 (ARGON / CARBON DIOXIDE) ARGN (ARGON)

Stainless Steel

ARGN (ARGON) HE AR25 (HELIUM/ARGON) ARGN HE (ARGON / HELIUM) ARGN (ARGON) HE ARGN (HELIUM / ARGON) ARGN (ARGON)

Nickel Copper Nickel Silicon Bronze

*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 and
size.

Notes

Work like a Pro!

Pros weld and cut safely. Read the safety rules at the beginning of this manual.

TM-231 242 Page 24

XMT 350 MPa

6-6. Remote Process Select

This power source can be used with wire feeders that support Remote Process Select. This feature allows the operator to switch the active welding process between MIG and Pulsed MIG at the wire feeder. To determine if the welding system is Remote Process Select capable, connect the wire feeder to the power source and review the power source display variations shown below.

. When used with an XMT power source,

the Process Select knob must be set to Pulsed MIG for Remote Process Select to be active.

50 25.0 50 MIG PULS

Power Source Display Wire Feeder with Remote Process Select Not Detected When the power source Right Display is blank, a wire feeder with Remote Process Select is not detected. Set the active weld process at the power source. Power Source Display Wire Feeder with Remote Process Select Detected When the power source Right Display is MIG, a wire feeder with Remote Process Select is detected and set for MIG operation. The active weld process can only be changed at the wire feeder. Power Source Display Wire Feeder with Remote Process Select Detected and Set for Pulsed MIG When the power source Right Display is PULS, a Remote Process Select wire feeder is detected and is set for Pulsed MIG operation. The active weld process can only be changed at the wire feeder. Using a Dual Wire Feeder with Remote Process Select When using a dual wire feeder with Remote Process Select, different weld programs for the left and right side can be selected. The power source MIG and Pulsed MIG programs for the left side of wire feeder are selected with the left side of the wire feeder active. The power source MIG and Pulsed MIG programs for the right side are selected with the right side of the wire feeder active. When the right side of the wire feeder is active, the power source Right Display will show a decimal point in the lower right hand corner as shown.

25.0 50

MIG. PULS.

Power Source Display Dual Wire Feeder with Right Side Active and Set for MIG

Decimal point indicates wire feeder right side is active. Power Source Display Dual Wire Feeder with Right Side Active and Set for Pulsed MIG

Decimal point indicates wire feeder right side is active.

XMT 350 MPa

TM-231 242 Page 25

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

!
1 Turn off power before making connections.

10 1

Positive (+) Weld Output Terminal 2 Negative () Weld Output Terminal 3 Ground Cable to Workpiece 4 Workpiece 5 Voltage Sensing Clamp 6 Gun 7 Gun Trigger Receptacle 8 Wire Feeder 9 Gas Hose 10 Gas Cylinder Use of shielding gas is dependant on Wire Type.

. The connection diagram illus2

trates DCEP (reverse polarity) suitable for all wires except self-shielded FCAW. The majority of self-shielded FCAW wires require DCEN (straight polarity).

8 4

5 6

804 843-B

TM-231 242 Page 26

XMT 350 MPa

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

2 5.0
6 7

8 9
226 611-A

!
1 2 3 4 5 6 7 8 9

Weld terminals are energized at all times in V-Sense Feeder welding mode. Mode Switch Volts Indicator Left Display Right Display Adjust Control Wire Type Indicator Arc Control Indicator Setup Button Gas Type Indicator

Operation While the Volts Indicator is lit under the Left Display, the Adjust Control is used to set desired preset voltage.

Rotate Adjust Control to select desired gas. Press the Setup Button again to confirm the selection. The unit will acknowledge a change of wire and gas information by displaying PROG LOAD momentarily. Arc Control (Inductance) Press the Setup Button repeatedly until the Arc Control indicator is lit. INDU appears on the Left Display, and the corresponding inductance setting appears on the Right Display. Rotate Adjust Control to select desired inductance setting from 0 to 100. Use lower inductance settings to stiffen the arc and reduce puddle fluidity. Use higher inductance settings to soften the arc and increase puddle fluidity. Refer to the MIG Wire and Gas Selection Table (see Section 6-3) for suggested inductance setting for the specific wire and gas being used.

. The Left Display toggling momentarily

pauses while the preset voltage is adjusted. Pressing the Setup Button allows adjustment of Arc Control, Wire Type, Gas Type and preset voltage.

. For best results, select the appropriate

Refer to MIG Wire and Gas Selection Table for available wires and gases (see Section 6-3). Selecting a Wire and Gas

Wire and Gas Type to match the actual wire and gas being used.

Setup For typical system setup connections refer to Section 6-7. Rotate Mode Switch to V-SENSE FEEDER position as shown. The Left Display toggles between open circuit voltage and preset voltage with the Volts Indicator lit.

Press the Setup Button repeatedly until the Wire Type indicator is lit. The active Wire Type will appear in the Left and Right Display. Rotate Adjust Control to select desired wire. Press the Setup Button again so the Gas Type indicator is lit. The active Gas Type will appear in the Left and Right Display.

. Each Wire and Gas Type combination

has independent preset voltage and inductance settings. These settings are preserved when the unit is turned off.

XMT 350 MPa

TM-231 242 Page 27

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

2 5.0 R200
7 8

9 10
226 611-A

!
1 2 3 4 5 6 7 8 9 10

Weld terminals are energized at all times in V-Sense Feeder welding mode. Mode Switch Volts Indicator Left Display Right Display Arc Length Indicator Adjust Control Wire Type Indicator Arc Control Indicator Setup Button Gas Type Indicator

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

. For best results, select the appropriate

Refer to Pulsed MIG Wire and Gas Selection Table for available wires and gases (see Section 6-5). Selecting a Wire and Gas

Higher settings narrow the arc cone, reduces puddle fluidity and crowns the weld bead appearance.

Wire and Gas Type to match the actual wire and gas being used.

. Each Wire and Gas Type combination

has independent Arc Length and SharpArc settings. These settings are preserved when the unit is turned off.

Arc Length Arc length corresponds to the level of energy needed to burn off the welding electrode. As wire feed speed increases, a higher arc length setting is required to burn off the additional wire. The arc length setting appears in the Left Display when the Arc Length Indicator is lit. Arc length can be adjusted from 0 to 100. Prior to arc initiation, the unit displays the letter R and a reference wire speed (IPM) on the Right Display. The reference wire speed can be used as a starting point for the wire speed setting at the feeder. The wire speed and arc length can then be further adjusted to achieve the desired arc length. The Configuration Option Menu (see Section 4-3) can be used to change the Arc Length setting from 0 to 100 to average arc voltage. Average arc voltage can be used as an alternative method to set the Pulsed MIG welding arc with the same parameters (voltage and wire speed) as a conventional MIG arc. Lower voltage settings correspond to tighter arc lengths while higher voltage settings correspond to longer arc lengths. If the voltage mode is selected, the average preset voltage will be displayed on the Left Display with the Volts Indicator lit.

Press the Setup Button repeatedly until the Wire Type indicator is lit. The active Wire Type will appear in the Left and Right Display. Rotate Adjust Control to select desired wire. Press the Setup Button again so the Gas Type indicator is lit. The active Gas Type will appear in the Left and Right Display. Rotate Adjust Control to select desired gas. Press the Setup Button again to confirm the selection. The unit will acknowledge a change of wire and gas information by displaying PROG LOAD momentarily. Arc Control (SharpArc) Press the Setup Button repeatedly until the Arc Control indicator is lit. SHRP appears on the Left Display, and the corresponding SharpArc setting appears on the Right Display. Rotate Adjust Control to select desired SharpArc setting from 0 to 50, default is 25. Adjusting the SharpArc setting changes the welding arc cone. Lower settings widen the arc cone, increases puddle fluidity and flattens the weld bead appearance.

Setup For typical system setup connections refer to Section 6-7. Rotate Mode Switch to V-SENSE FEEDER position as shown. The Left Display toggles between open circuit voltage and the arc length setting. The open circuit voltage is shown while the Volts Indicator is lit, and the arc length setting is shown while the Arc Length Indicator is lit. Operation While the Arc Length Indicator is lit under the Left Display, the Adjust Control is used to set desired arc length setting.

. The Left Display toggling momentarily

pauses while the arc length setting is adjusted. Pressing the Setup Button allows adjust-

TM-231 242 Page 28

XMT 350 MPa

SECTION 7 SMAW/CAC-A OPERATION

7-1. Typical Connection For SMAW And CAC-A Process
!
1 Turn off power before making connections. Electrode Holder (Carbon Arc)

For CAC-A process connect carbon arc cutting torch to to positive weld output terminal. 2 3 4 3 4 Electrode Holder Positive (+) Weld Output Terminal Remote 14 Receptacle

Connect desired remote control to remote 14 receptacle as required. 5 6 Compressed Air LIne Negative () Weld Output Terminal Workpiece

2 7 1
Ref. 804 842-B

XMT 350 MPa

TM-231 242 Page 29

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

85
6

226 611-A

!
1 2 3 4 5 6 7

Weld terminals are energized through the remote control in CC welding mode. Mode Switch Left Display Right Display Amps Indicator Adjust Control Arc Control Indicator Setup Button

. If the remote control has an amperage

Programmable Hot Start Press the Setup button repeatedly until HOT.S appears on the left display. HOT.S adjusts the Hot Start Amperage to Adaptive Hot Start (AUTO) or from Min (1) to Max (50). Adaptive Hot Start (AUTO) automatically chooses a default amperage. The Min (1) setting results in no hot start amperage. Higher numbers result in higher start amperage. Press the Setup button again so HOT.T appears on the left display. HOT.T adjusts the Hot Start Time to Adaptive Hot Start (AUTO) or from Min (1) to Max (50). Adaptive Hot Start (AUTO) automatically chooses a default time. The Min (1) setting results in no hot start time. Higher numbers result in longer start time. Press the Setup button to return to adjustment of preset amperage.

adjustment, the adjustment will function as a percentage of the preset amperage. Pressing the Setup Button allows adjustment of Arc Control, Hot Start Current, and Hot Start Time.

. For best results at the end of the weld,

Setup For typical system connections refer to Section 7-1. Rotate Mode Switch to CC position as shown. The preset amperage is shown in the Right Display with the Amps Indicator lit. Operation While the Amps Indicator is lit under the Right Display, the Adjust Control is used to set desired preset amperage. A remote control is required to turn on the weld output.

pull back the electrode quickly to extinguish the arc. Arc Control (Dig) Press the Setup Button so the Arc Control indicator is lit. DIG appears on the Left Display, and the corresponding dig setting appears on the Right Display. Rotate Adjust Control to select desired dig setting from 0 to 100. Dig control allows the arc characteristics, soft versus stiff, to be changed for specific applications and electrodes. Lower the dig setting for smooth running electrodes like E7018 and increase the dig setting for stiffer, more penetrating electrodes like E6010. Press the Setup Button repeatedly until the Arc Control light goes out to return to adjustment of preset amperage.

. Use

this mode for Air Carbon Arc (CACA) cutting and gouging. For best results, adjust dig setting to maximum.

TM-231 242 Page 30

XMT 350 MPa

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

7 2. 0

85
7

226 611-A

Weld terminals are energized at all times in Stick welding mode. 1 Mode Switch 2 Volts Indicator 3 Left Display 4 Right Display 5 Amps Indicator 6 Adjust Control 7 Arc Control Indicator 8 Setup Button Setup For typical system connections refer to Section 7-1. Rotate Mode Switch to STICK position as shown. The open circuit voltage is shown in the Left Display with the Volts Indicator lit, and the preset amperage is shown in the Right Display with the Amps Indicator lit. Operation While the Amps Indicator is lit under the Right Display, the Adjust Control is used to set desired preset amperage. Pressing the Setup Button allows adjustment of Arc Control, Hot Start Current, and Hot Start Time.

. For best results at the end of the weld,

pull back the electrode quickly to extinguish the arc. Arc Control (Dig) Press the Setup Button so the Arc Control indicator is lit. DIG appears on the Left Display, and the corresponding dig setting appears on the Right Display. Rotate Adjust Control to select desired dig setting from 0 to 100. Dig control allows the arc characteristics, soft versus stiff, to be changed for specific applications and electrodes. Lower the dig setting for smooth running electrodes like E7018 and increase the dig setting for stiffer, more penetrating electrodes like E6010. Press the Setup Button repeatedly until the Arc Control light goes out to return to adjustment of preset amperage.

Programmable Hot Start Press the Setup button repeatedly until HOT.S appears on the left display. HOT.S adjusts the Hot Start Amperage to Adaptive Hot Start (AUTO) or from Min (1) to Max (50). Adaptive Hot Start (AUTO) automatically chooses a default amperage. The Min (1) setting results in no hot start amperage. Higher numbers result in higher start amperage. Press the Setup button again so HOT.T appears on the left display. HOT.T adjusts the Hot Start Time to Adaptive Hot Start (AUTO) or from Min (1) to Max (50). Adaptive Hot Start (AUTO) automatically chooses a default time. The Min (1) setting results in no hot start time. Higher numbers result in longer start time. Press the Setup button to return to adjustment of preset amperage.

. Use

this mode for Air Carbon Arc (CACA) cutting and gouging. For best results, adjust dig setting to maximum.

XMT 350 MPa

TM-231 242 Page 31

7-4.

Optional Low Open Circuit Voltage (OCV) Welding Modes

Low OCV Operation The unit can be optionally configured for low open circuit voltage (OCV) operation in Stick and Scratch Start TIG modes. When the unit is configured for low OCV operation only a low sensing voltage (approximately 15 VDC) is present between the electrode and the workpiece prior to the electrode touching the workpiece. Consult a Factory Authorized Service Agent for information regarding how to configure the unit for low OCV welding operation.

Notes

TM-231 242 Page 32

XMT 350 MPa

Notes

XMT 350 MPa

TM-231 242 Page 33

SECTION 8 THEORY OF OPERATION

4 Boost Input Inductor L1 7 Input Pre-Regulator Module Mod1

5 Boost Snubber Inductor L2 8 Snubber Resistor Module RM1 9

6 Inverter Module Mod2

Bus Capacitors C12, C13

1 1 Phase or 3 Phase Input Power

2 Power Switch S1

3 10 Power Interconnect Board PC2 Current Transformer CT1

Bus Voltage Input Rectifier Voltage Input Boost Inductor Current Feedback Boost Gate Signal 20 Front Panel And Display Board PC3 21 Voltmeter V 22 Arc Control 24 Remote 14-Pin Receptacle RC50 Ribbon Cable 25 Process Selector Switch 26 Weld Process Control Positive (+) Output Voltage Feedback Negative () Output Voltage Feedback 21 Ammeter A 23 Voltage/ Amperage Adjust 27 Optional Auxiliary Power 115 VAC Receptacle 115 VAC

24 VAC

TM-231 242 Page 34

XMT 350 MPa

19 Output Stabilizer L3

15 Negative () Weld Output Receptacle

Work 16 Stick Boost Relay CR1 17 Stick Boost Inductor L4 18 Stick Boost Rectifier SR1

15 11 Series Capacitor C15 12 Main Transformer T1 13 Output Diodes D1 & D2 14 Positive (+) Weld Output Receptacle

Main Transformer Current Feedback Inverter Gating Signals 28 31

Output Current Feedback

Output Current Sensor HD1

35 Fan Motor FM1

36 Optional Gas Solenoid GS1

Electrode

29 Boost Control Control Board PC1

30 Control Power Module

Inverter Control 37 Secondary Heatsink Thermistor RT-1 34 VAC Center Tapped 38 Primary Heatsink Thermistor RT-2

665 VAC 32 Supplementary 115 VAC Protector CB1 33 Supplementary Protector CB2 34

Control Transformer T2 115 VAC

24 VAC

Control Circuit Primary Circuit Weld Circuit

Optional

XMT 350 MPa

TM-231 242 Page 35

Theory Of Operation Components

1 Primary Input Power 12 Main Transformer T1 Switching action of IGBTs in MOD2 creates the AC voltage source for T1 primary. T1 secondary outputs supply power to the weld circuit. 13 Output Diodes D1, D2 Rectifies the main secondary output of T1. 14 Output Current Sensor HD1 Provides weld output current feedback to PC1. 15 Positive (+) and Negative () Weld Output Receptacles Provide weld output and allow changing of output polarity. 16 Stick Boost Relay CR1 Provides on/off control of Stick boost output circuit. 17 Stick Boost Inductor L4 Limits current in the Stick boost output circuit. 18 Stick Boost Rectifier SR1 Rectifies the Stick boost secondary output of T1. 19 Output Stabilizer L3 Filters or smooths the DC weld output current. 20 User Interface Board PC3 Consists of Voltmeter V, Ammeter A, Arc Control, Voltage/Amperage Adjust, Remote 14pin receptacle, Process Selector Switch, and Weld Process Control. 21 Voltmeter V, Ammeter A See Section 4-1, Front Panel. 22 Arc Control Controls Dig in Stick process or Inductance in MIG process. See Section 4-1 Front Panel. 23 Voltage/Amperage Adjust Selects weld output voltage or amperage level. See Sections 4-1 and 4-2. 24 Remote 14-Pin Receptacle RC50 Provides connection for accessory equipment. See Sections 4-1, Front Panel, and 3-5, Remote 14 Receptacle Information. 25 Process Selector Switch Selects weld process. See Section 4-1, Front Panel. 26 Weld Process Control Controls weld output by automatically adjusting output current command signal to Inverter Control. Single or Three-Phase AC primary power supply. 2 Power Switch S1 27 Optional Auxiliary Power 115 VAC Receptacle Provides connection for auxiliary equipment to welding power source. 28 Control Board PC1 Contains the boost control, control power module, and inverter control. 29 Boost Control Controls switching of boost IGBT in MOD1 to regulate L1 current and the DC bus voltage. 30 Control Power Module Contains power supply for boost control power, and inverter IGBTs to create AC voltage source for T2 primary. 31 Inverter Control Controls the main inverter and snubber IGBTs within MOD2. Regulates the weld output current to the value received from weld process controller. Provides power to PC3. Drives fan motor and gas valve. Provides interface between primary and secondary thermistors and PC3. 32 Supplementary Protector CB1 Provides overload protection for remote 14-pin 115 VAC power, and optional 115 VAC receptacle. 33 Supplementary Protector CB2 Provides overload protection for remote 14-pin 24 VAC power. 34 Control Transformer T2 Provides power to inverter control on PC1, remote 14-pin receptacle, and optional 115 VAC receptacle. 35 Fan Motor FM1 Provides cooling of heatsinks and components mounted inside wind tunnel. The fan motor is thermostatically controlled and only runs when cooling is needed. Once unit is cooled to proper temperature, fan will continue to run for ten minutes. 36 Optional Gas Solenoid GS1 Provides on/off flow of shielding gas to the arc while TIG welding. 37 Secondary Heatsink Thermistor RT-1 Monitors temperature of secondary heatsink for fan motor control and overtemperature shutdown. 38 Primary Heatsink Thermistor RT-2 Monitors temperature of primary heatsink for fan motor control and overtemperature shutdown.

Provides on/off control of primary input power to welding power source. 3 Power Interconnect Board PC2

Provides electrical connections for L1, L2, MOD1, MOD2, RM1, C12 & C13. Precharge and bleeder resistors and snubber capacitors are mounted on PC2. 4 Boost Input Inductor L1

Required to boost input rectifier voltage to bus voltage. 5 Boost Snubber Inductor L2

Required to ensure softswitching of the boost IGBT located in MOD1. 6 Inverter Module MOD2

Contains the main inverter IGBTs, snubber IGBTs, main boost diode, and two boost snubber diodes. 7 Input PreRegulator Module MOD1

Contains the input rectifier diodes, boost IGBT, and one boost snubber diode. 8 Snubber Resistor Module RM1

Contains one boost snubber resistor and one inverter snubber resistor. 9 Bus Capacitors C12 & C13

Stores energy and filters the DC bus voltage for input boost and inverter. 10 Current Transformer CT1 Provides T1 current feedback to PC1. Used to protect inverter IGBTs in case of T1 primary overcurrent. 11 Series Capacitor C15 Provides protection against T1 saturation. Saturation occurs when the voltage across the transformer is not balanced. The unbalanced voltage appears as a DC offset voltage across the transformer and can cause a T1 primary overcurrent. The capacitor protects against this condition by blocking the DC offset.

TM-231 242 Page 36

XMT 350 MPa

SECTION 9 TROUBLESHOOTING
9-1. Checking Unit Before Applying Power

! !

Measure voltage of input capacitors according to Section 9-2 and be sure voltage is near zero before touching any parts. Although control board PC1 and power interconnect board PC2 are briefly checked here, more complete tests may be needed later for these parts. This procedure is simply to get a basic okay to power up unit.

. 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

XMT 350 MPa

TM-231 242 Page 37

PRE-POWER CHECKS
9-2. Measuring Input Capacitor Voltage
! !
5 Turn Off welding power source, and disconnect input power. Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged before working on unit. Power Interconnect Board PC2 Voltmeter Capacitor C12

Typical Bleeder Resistor 25 to 1000 ohm, 5 watt resistor

Remove cover 1 2 3

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

Measure the DC voltage across C12 (+) Positive Terminal and C12 () Negative Terminal on PC2 as shown until voltage drops to near 0 (zero) volts. 4 Capacitor C13 Measure the DC voltage across C13 (+) Positive Terminal and C13 () Negative Terminal on PC2 as shown until voltage drops to near 0 (zero) volts.

. If the capacitor voltage does not

drop to near zero after several minutes, use a bleeder resistor of between 25 and 1000 ohms, at least 5 watts, #16 AWG 1000 volts DC insulating rating wire to discharge the capacitor(s) . Typical Bleeder Resistor

An example of a typical bleeder resistor is shown on this page. Proceed with pre-power checks. 4 1 2

3 1 2

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

Test Equipment Needed: Positive (+) lead to C12 (+) terminal, Negative () lead to C12 () terminal

Ref. 803 721-B / 907 161

TM-231 242 Page 38

XMT 350 MPa

PRE-POWER CHECKS
9-3. Input Pre-Regulator Module (MOD1)
Test Equipment Needed:

! !

Read and follow safety information in Section 9-1 before proceeding. Wear an earth grounded wrist strap when performing pre-power and power off checks. Remove wrist strap before performing any checks or procedures with power applied to the machine. that shown. MOD1

. Board layout may differ from

1 Visually inspect MOD1 for damage. BUS Check all measurements for MOD1 (see Section 9-4). Component Side Of Board

RC3

. If any of the measurements

K D12

do not read correctly, replace MOD1 and MOD2. If an input SCR measures short also replace PC2. ent and must be installed in the proper location.

. MOD1 and MOD2 are differMatch the number on the side of each module to the number on PC2. S MOD1 is skiip 83 HEC S MOD2 is skiip 83 EC

AC1

TP1 L1-L2

AC2

The modules come as a kit with installation instructions that need to be followed entirely. Continue to the end of the pre-power checks.

AC3

L1

Ref. 907 161 / 246 337-A

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

Input Pre-Regulator Module MOD1 Boost IGBT Boost IGBT (w/Plug Removed From RC3) Boost Snubber Diode Input SCR Input SCR Input SCR Input Diode Input Diode Input Diode DVM Positive Lead BUS D12 Left L1-L2 L1 L1 L1 BUS BUS BUS DVM Negative Lead L1-L2 BUS TP1 AC1 AC2 AC3 AC1 AC2 AC3 DVM Diode 0.20 - 0.90 N/A 0.20 - 0.90 OL OL OL 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 DVM Ohms N/A 100k N/A N/A N/A N/A N/A N/A N/A

Input Pre-Regulator Module MOD1 Boost IGBT (w/Plug Removed From RC3) XMT 350 MPa

IGBT Tester Positive Lead - RED L1-L2

IGBT Tester Negative Lead - BLACK BUS

Gate RC3-2

TM-231 242 Page 39

PRE-POWER CHECKS
9-5. Inverter Module (MOD2)
!
1 Test Equipment Needed: Read and follow safety information in Section 9-1 before proceeding. Wear an earth grounded wrist strap when performing pre-power and power off checks. Remove wrist strap before performing any checks or procedures with power applied to the machine. that shown. MOD2

. Board layout may differ from

Component Side Of Board BUS +BUS TP2 1 Visually inspect MOD2 for damage. Check all measurements for MOD2 (see Section 9-6).

RC1
TP3 TP1 HF-XFMR

. If any of the measurements do

not read correctly, replace MOD2, MOD1.

. MOD1 and MOD2 are different and must be installed in the proper location. Match the number on the side of each module to the number on PC2. S MOD1 is skiip 83 HEC S MOD2 is skiip 83 EC The modules come as a kit with installation instructions that need to be followed entirely. Continue to the end of the pre-power checks.

TP4

L2

Ref. 907 161 / 246 337-A

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

Inverter Module MOD2 Boost Snubber Diode Boost Snubber Diode Main Boost Diode Inverter IGBT Inverter IGBT Snubber IGBT Snubber IGBT Inverter IGBT Gate (w/Plug Removed From RC1) Inverter IGBT Gate (w/Plug Removed From RC1) Snubber IGBT Gate (w/Plug Removed From RC1) Snubber IGBT Gate (w/Plug Removed From RC1) DVM Positive Lead TP1 L2 TP4 HF-XFMR BUS TP2 TP2 RC1-1 RC1-6 RC1-10 RC1-9 DVM Negative Lead TP4 TP4 +BUS +BUS HF-XFMR HF-XFMR TP3 HF-XFMR BUS TP2 TP2 DVM Diode 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 N/A N/A N/A N/A DVM Ohms N/A N/A N/A N/A N/A N/A N/A 100k 100k 100k 100k

Input Pre-Regulator Module MOD2 Inverter IGBT (w/Plug Removed From RC1) Inverter IGBT (w/Plug Removed From RC1) Snubber IGBT (w/Plug Removed From RC1) Snubber IGBT (w/Plug Removed From RC1) TM-231 242 Page 40

IGBT Tester Positive Lead - RED HF-XFMR +BUS HF-XFMR TP3

IGBT Tester Negative Lead - BLACK BUS HF-XFMR D9 Left D9 Left

Gate RC1-6 RC1-1 RC1-10 RC1-9 XMT 350 MPa

PRE-POWER CHECKS
9-7. Power Interconnect Board PC2
1 Test Equipment Needed:

R1

R8

Ref. 907 161 / 246 337-A

! !

Read and follow safety information in Section 9-1 before proceeding. 1 Wear an earth grounded wrist strap when performing pre-power and power off checks. Remove wrist strap before performing any checks or procedures with power 2

applied to the machine. Power Interconnect Board PC2 MOD1 And MOD2 Connecting Screws 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 (see Section 9-28).

. If any measurements failed, replace

PC2 and bus capacitors.

9-8. Power Interconnect Board PC2 Test Point Values

Power Interconnect Board PC2 Bleeder Resistor R1 Bleeder Resistor R8 DVM Positive Lead Center Bus +BUS DVM Negative Lead BUS Center Bus DVM Diode N/A N/A DVM Ohms 28k - 32k 28k - 32k

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

XMT 350 MPa

TM-231 242 Page 41

PRE-POWER CHECKS
9-9. Control Board PC1
1 RC5

D46 A K

RC3

1 2 3 4

8 7 6 5

Test Equipment Needed:

. Pin sequence of IC chips.

Ref. 907 161 / 242 814-C

! !

Read and follow safety information in Section 9-1 before proceeding. Wear an earth grounded wrist strap when performing pre-power and power off checks. Remove wrist strap before performing any

checks or procedures with power applied to the machine.

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

. Remove all
testing. 1

plugs from PC1 before

. If any of the measurements do not read

correctly, replace PC1. Continue to the end of the pre-power checks.

Control Board PC1

Visually inspect PC1 for damage.

9-10. Control Board PC1 Test Point Values

Pre-Regulator Control Buck IGBT Buck Diode Boost IGBT Gate Drive Boost IGBT Gate Drive Boost IGBT Gate Drive 60Hz Auxiliary Power Bridge Auxiliary Bridge IGBT Auxiliary Bridge IGBT Auxiliary Bridge IGBT Auxiliary Bridge IGBT TM-231 242 Page 42 DVM Positive Lead D46 Anode RC3 Pin 6 RC3 Pin 4 RC3 Pin 4 RC3 Pin 3 DVM Positive Lead RC5 Pin 3 RC5 Pin 1 RC3 Pin 6 RC3 Pin 6 DVM Negative Lead RC2 Pin 1 U6 Pin 5 RC3 Pin 2 RC3 Pin 3 RC3 Pin 4 DVM Negative Lead RC2 Pin 1 RC2 Pin 1 RC5 Pin 3 RC5 Pin 1 DVM Diode 0.20 - 0.90 0.20 - 0.90 0.20 - 1.50 N/A 0.20 - 0.90 DVM Diode 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 DVM Ohms N/A N/A N/A 1.9k - 2.1k N/A DVM Ohms N/A N/A N/A N/A XMT 350 MPa

RC2

PRE-POWER CHECKS
9-11. Power Switch (S1)
! !
Read and follow safety information in Section 9-1 before proceeding. Wear an earth grounded wrist strap when performing pre-power and power off checks. Remove wrist strap before performing any checks or procedures with power applied to the machine. Power Switch S1

Visually inspect S1 for damage. Check switch mechanical operation by turning switch On and Off several times. Switch should snap sharply between the On and Off positions. Check switch electrical operation by checking continuity across S1 contacts with switch in the On position. With switch in the Off position, ohmmeter should read open. Replace switch if necessary. Continue to the end of the pre-power checks.

Electrical Schematic

Test Equipment Needed:

Ref. 907 161 / Ref. 183 484

XMT 350 MPa

TM-231 242 Page 43

PRE-POWER CHECKS
9-12. Output Diodes D1, D2
! !
Read and follow safety information in Section 9-1 before proceeding. Wear an earth grounded wrist strap when performing pre-power and power off checks. Remove wrist strap before performing any checks or procedures with power applied to the machine. Diode D1 Diode D2

+
Weld Output Receptacles

1 2

Visually inspect D1 and D2 for damage. Check all measurements for output diodes D1 and D2 (see Section 9-13).

. If any of the measurements do

Continue to the end of the pre-power checks.

not read correctly, replace both D1 and D2.

Test Equipment Needed: 1

Diodes D1, D2

Ref. 804 980-A / 804 979-A

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

Output Diodes D1 And D2 D1 D2 DVM Positive Lead Terminal Anode Terminal Anode DVM Negative Lead Secondary Heatsink Secondary Heatsink DVM Diode 0.10 - 0.90 0.10 - 0.90 DVM Ohms N/A N/A

TM-231 242 Page 44

XMT 350 MPa

PRE-POWER CHECKS
9-14. Stick Boost Rectifier (SR1)
! !
Read and follow safety information in Section 9-1 before proceeding. Wear an earth grounded wrist strap when performing pre-power and power off checks. Remove wrist strap before performing any checks or procedures with power applied to the machine. Stick Boost Rectifier SR1

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

. If any of the measurements do

not read correctly, replace SR1. 1

3 4

2 1

Test Equipment Needed:

Ref. 804 980-A / 804 979-A

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

Stick Boost Rectifier SR1 SR1 SR1 SR1 SR1 DVM Positive Lead Terminal 2 Terminal 4 Terminal 3 Terminal 3 DVM Negative Lead Terminal 1 Terminal 1 Terminal 2 Terminal 4 DVM Diode 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 DVM Ohms N/A N/A N/A N/A

XMT 350 MPa

TM-231 242 Page 45

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

9-16. Troubleshooting Table

!
Remove earth grounded wrist strap before performing any checks or procedures with power applied to the machine. Section 12 for parts location. when servicing this unit.

. See Section 9-18 for test points and values and . Use MILLER Testing Booklet (Part No. 150 853) . See the MILLER Extranet for service memos that
may aid in the repair of this product.

Trouble No weld output; unit completely inoperative.

Remedy 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, and check 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 Sections 9-21 thru 9-22, and also see Section 9-19). Check power interconnect board PC2 and connections, and replace if necessary (see Power Off Checks 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. Check control board PC1 and connections, and replace if necessary (see Power Off Checks in Sections 9-21 thru 9-22, and also see Section 9-19). Check front panel/display board PC3 and connections, and replace if necessary (see Section 9-31).

Low weld output with no control.

Check input and output voltages of hall device HD1 (see Section 9-18). Replace HD1 if necessary. Check control board PC1 and connections, and replace if necessary (see Power Off Checks in Sections 9-21 thru 9-22, and also see Section 9-19). Check front panel/display board PC3 and connections, and replace if necessary (see Section 9-31).

Maximum weld output with no control.

Check input and output voltages of hall device HD1 (see Section 9-18). Replace HD1 if necessary. Check control board PC1 and connections, and replace if necessary (see Power Off Checks in Sections 9-21 thru 9-22, and also see Section 9-19). Check front panel/display board PC3 and connections, and replace if necessary (see Section 9-31).

Limited output and low open circuit voltage (OCV).

Check for proper input and output connections 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.

TM-231 242 Page 46

XMT 350 MPa

Always check unit before applying power (see Sections 9-1 thru 9-10). Trouble Limited output and low open circuit voltage (OCV). (Continued) Remedy Check if Low Open Circuit Mode Operation is enabled (see Section 7-4). Check control board PC1 and connections, and replace if necessary (see Power Off Checks in Sections 9-21 thru 9-22, and also see Section 9-19). Check front panel/display board PC3 and connections, and replace if necessary (see Section 9-31). 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. If a remote accessory is connected to remote 14 receptacle RC50: Check all remote accessory connections (proper pin/socket alignment). Check accessory amperage control potentiometer resistance and connections, and replace if necessary. Check input and output voltages of hall device HD1 (see Section 9-18). Replace HD1 if necessary. Check control board PC1 and connections, and replace if necessary (see Power Off Checks in Sections 9-21 thru 9-22, and also see Section 9-19). Check front panel/display board PC3 and connections, and replace if necessary (see Section 9-31). No 24 volt AC output at Remote 14 receptacle RC50. Reset supplementary protector CB2 if necessary (see Section 3-6). Check receptacle wiring and connections. No 115 volt AC output at Remote 14 receptacle RC50 or optional duplex receptacle RC2. Reset supplementary protector CB1 if necessary (see Section 3-6).

Check receptacle wiring and connections. Fan motor does not run after approximately four minutes of operation at rated 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 Section 9-17). Check fan motor FM (see Section 9-18) and replace fan motor if necessary. Wandering arc; poor control of arc direction. Use proper size tungsten. Use properly prepared tungsten. Reduce gas flow rate. Tungsten electrode oxidizing and not remaining bright after conclusion of weld. Shield weld zone from drafts. Increase postflow time. Check and tighten all gas fittings. Water in torch. Refer to torch manual.

XMT 350 MPa

TM-231 242 Page 47

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

9-17. Help Displays . All directions are in reference to the front

of the unit. All circuitry referred to is located inside the unit.

HELP HELP HELP HELP HELP

1 2 3 5 6

Help 1 Display Indicates a malfunction in the primary power circuit. If this display is shown, contact a Factory Authorized Service Agent.

Help 2 Display Indicates a malfunction in the thermal protection circuitry. If this display is shown, contact a Factory Authorized Service Agent.

Help 3 Display Indicates the left side of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 2-4). Operation will continue when the unit has cooled.

Help 5 Display Indicates the right side of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 2-4). Operation will continue when the unit has cooled.

Help 6 Display Indicates operation at maximum input current. The unit has a maximum allowable input current limit. As the line voltage decreases, the required input current increases. If the line voltage is too low, the output power is limited by the input current. When this limit is reached, the unit automatically reduces output power to continue operation. If this display is shown, have a qualified electrician check the input voltage.

HELP HELP

8 25

Help 8 Display Indicates a malfunction in the secondary power circuit of the unit. If this display is shown, contact a Factory Authorized Service Agent.

Help 25 Display Indicates machine has reached duty cycle limits (see Section 2-4). Unit must be left on to power the fan for cooling. Operation will continue when unit has cooled.

TM-231 242 Page 48

XMT 350 MPa

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

Notes

MATERIAL THICKNESS GAUGE

XMT 350 MPa

TM-231 242 Page 49

229895

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

9-18. Troubleshooting Circuit Diagram

Resistance Values a) Voltage Readings a) Tolerance 10% unless specified b) Reference single arrow: reference to circuit common (lead 42); double arrow: reference to points indicated c) Wiring Diagram see Section 11 V1 V2, V3 V4 V5 V6, V7 V8 V9 665 volts AC RMS 17 volts AC RMS 115 volts AC RMS 24 volts AC RMS 470 volts DC 115 volts AC RMS when FM is running 24 volts DC when Relay is energized; Relay energized in Stick mode with output current greater than 10 amps and preset current less than 225 amps 24 volts DC when gas is flowing; see Section 3-7 for gas valve operation +15 volts DC 15 volts DC 1 volt DC per 100 amperes of weld output 72 volts DC open circuit voltage in Scratch Start TIG, TIG, MIG, Pulse MIG, CC, Stick and V-Sense feeder modes. b) Tolerance 10% unless specified Turn Off unit and disconnect input power before checking resistance Less than 1 ohm 190 210 ohms

R1 thru R6, R9 R7 and R8

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

. No calibration available for voltmeter V or ammeter A.

V10 V11 V12 V13 V14

V5

. 14 volts DC in Stick and Scratch

Start TIG modes (Effective with MA100311A) when low open circuit voltage mode is enabled (See Section 7-4). V4 V3 V2 V1

See Section 9-32 for RC50 information

See Section 9-31 for PC3 information V14

Test Equipment Needed:

HIGH VOLTAGE: Do not measure without proper instrumentation.

. V1 thru V5 and V8 use only true RMS meter

to obtain correct voltage reading.

TM-231 242 Page 50

XMT 350 MPa

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

See Section 9-25 for PC2 information R1 R2 R7 R8 R4

V6 V7

R9

R6 R5 R3 V14

V11 V12 Approx. 35K ohms at 705 F (215 C)

{
V8 V9 V10

V13

See Section 9-19 for PC1 information

256 234-A

XMT 350 MPa

TM-231 242 Page 51

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

9-19. Control Board PC1 Testing Information (Use with Section 9-20)
!
1 Measure voltage of input capacitors according to Section 9-2, and be sure voltage is near zero before touching any parts.

Be sure plugs are secure before applying power. See Section 9-20 for specific values during testing. 1 Control Board PC1

Test Equipment Needed:

Ref. 242 814-C / 907 161

TM-231 242 Page 52

XMT 350 MPa

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

9-20. Control Board PC1 Test Point Values

PC1 Voltage Readings a) Tolerance 10% unless specified b) Reference to circuit common (lead 42) unless noted
Value

Receptacle RC1

Pin

Type 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 2 3 4 RC3 Input Input Primary (+) bus; regulated to 940 volts DC with respect to primary () bus. Not used Not used Primary (+) rectifier; rectified primary line volts.

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 2 3 4 5 6 7 8 9 10 11 12 13 14 RC5 Input Input Output Precom Precom Precom Input Input Output Output Output Do not measure Boost inductor current feedback; 1 volt DC per 16 amps of boost inductor current +15 volts DC; regulated with respect to primary () bus 12 volts DC; regulated with respect to primary () bus Do not measure Boost IGBT gate drive signal Do not measure Boost IGBT gate drive signal return Circuit common referenced to primary () bus Circuit common referenced to primary () bus Circuit common referenced to primary () bus Do not measure Main transformer current sense CT; senses overcurrent in T1 transformer primary Do not measure Main transformer current sense CT return Precharge relay coil return; 0 volts DC = relay contacts open, 12 volts DC = relay contacts closed with respect to primary () bus Not used Do not measure Test point, used to test board only Do not measure Test point, used to test board only

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 2 3 Output Output Control transformer primary; 665 volts AC RMS with respect to RC5 pin 3 Not Used Control transformer primary; 665 volts AC RMS with respect to RC5 pin 1

XMT 350 MPa

TM-231 242 Page 53

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

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

Receptacle RC6 Pin 1 Type Input Value Output reference; 1 volt DC per 42.5 amperes of weld output when machine is under load; when mode switch in TIG mode, adjust control set at minimum = 0 volts DC, adjust control set at maximum = 10 volts DC Voltage feedback; 1 volt DC per 10 volts DC of weld output Current feedback; 1 volt DC per 100 amperes of weld output Not Used Input Output enable; 0 volts DC = ON, +12.5 volts DC = OFF Not Used Boost relay coil return; +24 volts DC = relay contacts open, less than +1 volts DC = relay contacts closed Gas valve coil return; +24 volts DC = valve closed (no gas flow), less than +1 volts DC = valve open Input Fan enable; +5 volts DC = fan on, 15 volts DC = fan off Not Used Output Main transformer overcurrent detect; +.7 volts DC = OK, +3.3 volts DC = T1 primary overcurrent = HELP 1 Not Used Input GND Output GND Output GND Output GND Output Output Output Output Output Input Output Input +3.0 volts DC reference voltage for thermistors Circuit common referenced to chassis Secondary side thermistor return; +1.2 volts DC at 25C thermistor temperature (Prior To LJ400071A +.473 volts DC) Circuit common referenced to chassis Primary side thermistor return; +1.2 volts DC at 25C thermistor temperature (Prior To LJ400071A +.473 volts DC) Circuit common referenced to chassis Foldback; decreases weld output if input bus voltage drops, 0 volts = OK, +15 volts DC 15Khz pwm squarewave = foldback Circuit common referenced to chassis +24 volts DC, unregulated DC voltage with respect to GND +24 volts DC, unregulated DC voltage with respect to GND 24 volts DC, unregulated DC voltage with respect to GND 24 volts DC, unregulated DC voltage with respect to GND +3 volts DC reference voltage for secondary side thermistor Secondary side thermistor return; +1.2 volts DC at 25C thermistor temperature (Prior To LJ400071A +.473 volts DC) +3 volts DC reference voltage for primary side thermistor Primary side thermistor return; +1.2 volts DC at 25C thermistor temperature (Prior To LJ400071A +.473 volts DC)

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 RC7 1 2 RC8 1 2

Input Output

TM-231 242 Page 54

XMT 350 MPa

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

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

RC9 1 2 3 4 5 6 RC10 1 2 3 4 RC11 1 2 3 4 RC12 1 2 3 4 5 6 7 8 Input Input Input Chassis Input Output Output Output Input Output Output GND Output Output Output Output Output Do not measure Test point, used to test board only Do not measure Test point, used to test board only Do not measure Weld output current sensor signal +15 volts DC power to current sensor 15 volts DC power to current sensor Weld output current sensor signal common 115 volts AC RMS with respect to GND; power feed to fan Fan power return; measure with respect to RC101, 115 volts AC RMS = fan on, less than 20 volts AC RMS = fan off Do not measure Test point, used to test board only Do not measure Test point, used to test board only +24 volts output to boost relay coil Boost relay coil return; +24 volts DC = relay contacts open, less than +1 volts DC = relay contacts closed +24 volts output to gas valve coil Gas valve coil return; +24 volts DC = valve closed (no gas flow), less than +1 volts DC = valve open Not Used 34 volts AC RMS; measure with respect to RC12 pin 4, power supply used to create +24/24 volts DC Power source chassis; circuit common (GND) on this pin bonded to chassis thru wire 34 volts AC RMS; measure with respect to RC12 pin 2, power supply used to create +24/24 volts DC Not Used Center tap of 34 volt AC connected to circuit common (GND) on board Not Used 115 volts AC RMS

Notes
OHM'S LAW VOLTAGE = CURRENT X RESISTANCE CURRENT = VOLTAGE RESISTANCE RESISTANCE = VOLTAGE CURRENT

XMT 350 MPa

TM-231 242 Page 55

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

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

A RC9 1 U1

K U4 U5 RC5

D37 D41 D42

A D49

D51 U6 D46

D44 D43 U13 D38 D39 U16

D18 A

D11

D20 K

U17

RC3

Test Equipment Needed: 1 2 3 4 8 7 6 5

. Pin sequence of IC chips.

Ref. 220 468-C / 907 161

! !

Read and follow safety information in Section 9-1 before proceeding. Wear an earth grounded wrist strap when performing power off checks. Remove wrist strap before

performing any checks or procedures with power applied to the machine.

Control Board PC1

Check all measurements for PC1.

. Remove all plugs from PC1 before

testing.

. If

any measurements failed, replace PC1.

TM-231 242 Page 56

XMT 350 MPa

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

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

Pre-Regulator Control Buck IGBT Gate Drive IC U6 Inverter Control Inverter IGBT Gate Drive IC U16 Inverter IGBT Gate Drive IC U16 Inverter IGBT Gate Drive IC U17 Inverter IGBT Gate Drive IC U17 Inverter IGBT Gate Drive IC U13 Inverter IGBT Gate Drive IC U13 Inverter IGBT Gate Drive IC U16 Inverter IGBT Gate Drive IC U16 Inverter IGBT Gate Drive IC U17 Inverter IGBT Gate Drive IC U17 Inverter IGBT Gate Drive IC U13 Inverter IGBT Gate Drive IC U13 60Hz Auxiliary Power Bridge Auxiliary Bridge IGBT Gate Drive IC U1 Auxiliary Bridge IGBT Gate Drive IC U1 Auxiliary Bridge IGBT Gate Drive IC U1 Auxiliary Bridge IGBT Gate Drive IC U1 Auxiliary Bridge IGBT Gate Drive IC U4 Auxiliary Bridge IGBT Gate Drive IC U5 D37 D38 D39 D42 D43 D44 D11 D20 D18 D41 D46 D49 D51 DVM Positive Lead U6 Pin 6 DVM Positive Lead RC9 Pin 6 RC9 Pin 6 RC9 Pin 6 RC9 Pin 6 RC9 Pin 6 RC9 Pin 6 U16 Pin 5 U16 Pin 7 U17 Pin 5 U17 Pin 7 U13 Pin 5 U13 Pin 7 DVM Positive Lead RC3 Pin 6 (PRECOM) U1 Pin 5 RC3 Pin 6 (PRECOM) U1 Pin 7 RC5 Pin 1 RC5 Pin 3 D37 Anode D38 Anode D39 Anode D42 Anode D43 Anode D44 Anode D11 Anode D20 Anode D18 Anode D41 Anode D46 Anode D49 Anode D51 Anode DVM Negative Lead U6 Pin 7 DVM Negative Lead U16 Pin 5 U16 Pin 7 U17 Pin 5 U17 Pin 7 U13 Pin 5 U13 Pin 7 RC9 Pin 4 RC9 Pin 4 RC9 Pin 4 RC9 Pin 4 RC9 Pin 4 RC9 Pin 4 DVM Negative Lead U1 Pin 5 U1 Pin 6 U1 Pin 7 U1 Pin 6 U5 Pin 7 U4 Pin 7 D37 Cathode D38 Cathode D39 Cathode D42 Cathode D43 Cathode D44 Cathode D11 Cathode D20 Cathode D18 Cathode D41 Cathode D46 Cathode D49 Cathode D51 Cathode DVM Diode 0.20 - 0.90 DVM Diode 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 DVM Diode 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.10 - 0.30 0.20 - 0.90 0.10 - 0.30 DVM Ohms N/A DVM Ohms N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A DVM Ohms N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

XMT 350 MPa

TM-231 242 Page 57

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

9-23. Control Board PC1 - Power Off Checks (Effective With MA070470A)
A 1 U1 K U4 U5 RC5 A RC9 D49 K

D37 D41 D42

D51 U6 D46

D61

D44 D43 U13 D38 D39 U16

D18 A

D11

D20 K

U17

RC3

Test Equipment Needed: 1 2 3 4 8 7 6 5

. Pin sequence of IC chips.

Ref. 242 814-C / 907 161

! !

Read and follow safety information in Section 9-1 before proceeding. Wear an earth grounded wrist strap when performing power off checks. Remove wrist strap before

performing any checks or procedures with power applied to the machine.

Control Board PC1

Check all measurements for PC1.

. Remove all plugs from PC1 before

testing.

. If

any measurements failed, replace PC1.

TM-231 242 Page 58

XMT 350 MPa

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

9-24. Control Board PC1 Power Off Checks (Effective With MA070470A)
Pre-Regulator Control Buck IGBT Gate Drive IC U6 Inverter Control Inverter IGBT Gate Drive IC U16 Inverter IGBT Gate Drive IC U16 Inverter IGBT Gate Drive IC U17 Inverter IGBT Gate Drive IC U17 Snubber IGBT Gate Drive IC U13 Snubber IGBT Gate Drive IC U13 Inverter IGBT Gate Drive IC U16 Inverter IGBT Gate Drive IC U16 Inverter IGBT Gate Drive IC U17 Inverter IGBT Gate Drive IC U17 Snubber IGBT Gate Drive IC U13 Snubber IGBT Gate Drive IC U13 60Hz Auxiliary Power Bridge Auxiliary Bridge IGBT Gate Drive IC U1 Auxiliary Bridge IGBT Gate Drive IC U1 Auxiliary Bridge IGBT Gate Drive IC U1 Auxiliary Bridge IGBT Gate Drive IC U1 Auxiliary Bridge IGBT Gate Drive IC U4 Auxiliary Bridge IGBT Gate Drive IC U5 D37 D38 D39 D42 D43 D44 D11 D20 D18 D41 D46 D49 D51 D61 DVM Positive Lead U6 Pin 6 DVM Positive Lead RC9 Pin 6 RC9 Pin 6 RC9 Pin 6 RC9 Pin 6 RC9 Pin 6 RC9 Pin 6 U16 Pin 5 U16 Pin 7 U17 Pin 5 U17 Pin 7 U13 Pin 5 U13 Pin 7 DVM Positive Lead RC3 Pin 6 (PRECOM) U1 Pin 5 RC3 Pin 6 (PRECOM) U1 Pin 7 RC5 Pin 1 RC5 Pin 3 D37 Anode D38 Anode D39 Anode D42 Anode D43 Anode D44 Anode D11 Anode D20 Anode D18 Anode D41 Anode D46 Anode D49 Anode D51 Anode D61 Anode DVM Negative Lead U6 Pin 7 DVM Negative Lead U16 Pin 5 U16 Pin 7 U17 Pin 5 U17 Pin 7 U13 Pin 5 U13 Pin 7 RC9 Pin 4 RC9 Pin 4 RC9 Pin 4 RC9 Pin 4 RC9 Pin 4 RC9 Pin 4 DVM Negative Lead U1 Pin 5 U1 Pin 6 U1 Pin 7 U1 Pin 6 U5 Pin 7 U4 Pin 7 D37 Cathode D38 Cathode D39 Cathode D42 Cathode D43 Cathode D44 Cathode D11 Cathode D20 Cathode D18 Cathode D41 Cathode D46 Cathode D49 Cathode D51 Cathode D61 Cathode DVM Diode 0.10 - 0.30 DVM Diode 0.10 - 0.30 0.10 - 0.30 0.10 - 0.30 0.10 - 0.30 0.10 - 0.30 0.10 - 0.30 0.10 - 0.30 0.10 - 0.30 0.10 - 0.30 0.10 - 0.30 0.10 - 0.30 0.10 - 0.30 DVM Diode 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.10 - 0.30 0.10 - 0.30 0.20 - 0.90 0.20 - 0.90 0.10 - 0.30 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 DVM Ohms N/A DVM Ohms N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A DVM Ohms N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

XMT 350 MPa

TM-231 242 Page 59

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

9-25. Power Interconnect Board PC2 Testing Information (Use with Section 9-26)
!
Measure voltage of input capacitors according to Section 9-2, and be sure voltage is near zero before touching any parts.

Be sure plugs are secure before applying power. See Section 9-26 for specific values during testing. 1 Power Interconnect Board PC2

Test Equipment Needed:

Ref. 246 337-A / 907 161

TM-231 242 Page 60

XMT 350 MPa

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

9-26. Power Interconnect Board PC2 Test Point Values

PC2 Voltage Readings a) Tolerance 10% unless specified b) Reference to circuit common (lead 42) unless noted
Value

Receptacle RC1

Pin

Type 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 2 3 4 RC3 Output Output Primary (+) bus; regulated to 940 volts DC with respect to primary () bus Not Used Not Used Primary (+) rectifier; rectified primary line volts

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 2 3 4 5 6 7 8 RC6 Input Output Input Precom Precom Input Input Do not measure Boost IGBT gate drive signal return Do not measure Boost IGBT gate drive signal Do not measure Boost inductor current feedback 12 volts DC; regulated with respect to primary () bus, 12 volts DC power to boost inductor current sensor Circuit common referenced to primary () bus Circuit common referenced to primary () bus Precharge relay coil return; 0 volts DC = relay contacts open, 12 volts DC = relay contacts closed with respect to primary () bus +15 volts DC; regulated with respect to primary () bus, +15 volts DC power to boost inductor current sensor

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 2 3 4 5 6 Snubber resistor1; input boost snubber, located in resistor module mounted to primary heat sink Not Used Snubber resistor2; inverter snubber, located in resistor module mounted to primary heat sink Snubber resistor1; input boost snubber, located in resistor module mounted to primary heat sink Not Used Snubber resistor2; inverter snubber, located in resistor module mounted to primary heat sink

XMT 350 MPa

TM-231 242 Page 61

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

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 with the primary supply, and with power circuit components not soldered in the pcb. Voltages on this receptacle can exceed 900 volts DC from chassis (GND). Type Power Power Power Power Power Power Power Power Power Power Value Primary AC mains phase 1; line voltage, measure with respect to AC2 or AC3 Primary AC mains phase 2; line voltage, measure with respect to AC1 or AC3 Primary AC mains phase 3; line voltage, measure with respect to AC1 or AC2 Input boost inductor; rectified line voltage, measure with respect to () bus Common point between input boost inductor and boost IGBT snubber inductor Boost IGBT snubber inductor High frequency weld power transformer primary (+) Bus; regulated to 940 volts DC with respect to () bus () Bus; power circuit common Bus capacitors center point; regulated to 470 volts DC with respect to () bus

Receptacle AC1 AC2 AC3 L1 L1-L2 L2 HF-XFMR C13 (+) C12 () Center Bus

Pin

Notes
MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 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)

TM-231 242 Page 62

XMT 350 MPa

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

Notes

MATERIAL THICKNESS GAUGE

XMT 350 MPa

TM-231 242 Page 63

229895

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

9-27. Power Interconnect Board (PC2) - Power Off Checks (Prior To MB510232A)
1 Test Equipment Needed:

K BUS Center Bus +BUS Q2 D11 D10

D8

R14 D13 K A D12 R11 R12 R10

D9 Q1 D1 D2

AC1 D3 D4

AC2

AC3

Ref. 907 161 / 232 403-B

! !

Read and follow safety information in Section 9-1 before proceeding. Wear an earth grounded wrist strap when performing power off checks. Remove wrist strap before performing any checks or proce-

dures with power applied to the machine.

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

. Remove all
testing. 1

plugs from PC2 before

Power Interconnect Board PC2

. If any measurements failed, replace

PC2.

TM-231 242 Page 64

XMT 350 MPa

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

9-28. Power Interconnect Board (PC2) - Power Off Checks (Prior To MB510232A)
Power Interconnect Board PC2 Pre-Charge Resistor R14 SCR Gate Resistor R10 SCR Gate Resistor R11 SCR Gate Resistor R12 Pre-Charge Diode D5 Pre-Charge Diode D6 Pre-Charge Diode D7 Boost Gate Protection Diode D12 Boost Gate Protection Diode D13 Inverter Gate MOSFET Q1 Inverter Gate MOSFET Q2 Inverter Gate Protection Diode D1 Inverter Gate Protection Diode D2 Inverter Gate Protection Diode D3 Inverter Gate Protection Diode D4 Snubber Gate Protection Diode D8 Snubber Gate Protection Diode D9 Snubber Gate Protection Diode D10 Snubber Gate Protection Diode D11 DVM Positive Lead R14 Bottom R10 Left R11 Left R12 Left AC3 AC2 AC1 D12 Anode D13 Anode Q1-S (Source) Q2-S (Source) D1 Anode D2 Anode D3 Anode D4 Anode D8 Anode D9 Anode D10 Anode D11 Anode DVM Negative Lead R14 Top R10 Right R11 Right R12 Right R14 Top R14 Top R14 Top D12 Cathode D13 Cathode Q1-D (Drain) Q2-D (Drain) D1 Cathode D2 Cathode D3 Cathode D4 Cathode D8 Cathode D9 Cathode D10 Cathode D11 Cathode DVM Diode N/A N/A N/A N/A 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 DVM Ohms 200 10 - 16.5 10 - 16.5 10 - 16.5 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Notes

XMT 350 MPa

TM-231 242 Page 65

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

9-29. Power Interconnect Board (PC2) - Power Off Checks (Effective With MB510232A)
1 Test Equipment Needed:

K Q2

A D1

R14 D9 Q1 D2

K D12 R11 R12 R10

AC1 D3

AC2

AC3

Ref. 907 161 / 246 337-A

! !

Read and follow safety information in Section 9-1 before proceeding. Wear an earth grounded wrist strap when performing power off checks. Remove wrist strap before performing any checks or proce-

dures with power applied to the machine.

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

. Remove all
testing. 1

plugs from PC2 before

Power Interconnect Board PC2

. If any measurements failed, replace

PC2.

TM-231 242 Page 66

XMT 350 MPa

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

9-30. Power Interconnect Board (PC2) - Power Off Checks (Effective With MB510232A)
Power Interconnect Board PC2 Pre-Charge Resistor R14 SCR Gate Resistor R10 SCR Gate Resistor R11 SCR Gate Resistor R12 Pre-Charge Diode D5 Pre-Charge Diode D6 Pre-Charge Diode D7 Boost Gate Protection Diode D12 Inverter Gate MOSFET Q1 Inverter Gate MOSFET Q2 Inverter Gate Protection Diode D2 Inverter Gate Protection Diode D3 Snubber Gate Protection Diode D9 DVM Positive Lead R14 Bottom R10 Left R11 Left R12 Left AC3 AC2 AC1 D12 Left Q1-S (Source) Q2-S (Source) D2 Left D3 Left D9 Left DVM Negative Lead R14 Top R10 Right R11 Right R12 Right R14 Top R14 Top R14 Top D12 Right Q1-D (Drain) Q2-D (Drain) D2 Right D3 Right D9 Right DVM Diode N/A N/A N/A N/A 0.20 - 0.90 0.20 - 0.90 0.20 - 0.90 N/A 0.20 - 0.90 0.20 - 0.90 N/A N/A N/A DVM Ohms 200 10 - 16.5 10 - 16.5 10 - 16.5 N/A N/A N/A 100k N/A N/A 100k 100k 100k

Notes

XMT 350 MPa

TM-231 242 Page 67

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

9-31. Front Panel/Display Board PC3 Testing Information (Use with Section 9-32)
!
Measure voltage of input capacitors according to Section 9-2, and be sure voltage is near zero before touching any parts.

Be sure plugs are secure before applying power. See Section 9-32 for specific values during testing. 1 Front Panel/Display Board PC3

Test Equipment Needed:

Ref. 242 727-C / 804 980-A

TM-231 242 Page 68

XMT 350 MPa

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

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

PC3 Voltage Readings a) Tolerance 10% unless specified b) Reference to circuit common (lead 42) unless noted
Value Output reference; 1 volt DC per 42.5 amperes of weld output when machine is under load; when mode switch in TIG mode, adjust control set at minimum = 0 volts DC, adjust control set at maximum = 10 volts DC Voltage feedback; 1 volt DC per 10 volts DC of weld output Current feedback; 1 volt DC per 100 amperes of weld output Not Used Output Output enable; 0 volts DC = ON, +12.5 volts DC = OFF Not Used Boost relay coil return; +24 volts DC = relay contacts open, less than +1 volts DC = relay contacts closed Gas valve coil return; +24 volts DC = valve closed (no gas flow), less than +1 volts DC = valve open Output Fan enable; +5 volts DC = fan on, 15 volts DC = fan off Not Used Input Main transformer overcurrent detect; +.7 volts DC = OK, +3.3 volts DC = T1 primary current = HELP 1 Not Used Output GND Input GND Input GND Input GND Input Input Input Input Input +3.0 volts DC reference voltage for thermistors Circuit common referenced to chassis Secondary side thermistor return; +1.2 volts DC at 25C thermistor temperature (Prior To LJ400071A +.473 volts DC) Circuit common referenced to chassis Primary side thermistor return; +1.2 volts DC at 25C thermistor temperature (Prior To LJ400071A +.473 volts DC) Circuit common referenced to chassis Foldback; decreases weld output if input bus voltage drops, 0 volts = OK, +15 volts DC 15Khz pwm squarewave = foldback Circuit common referenced to chassis +24 volts DC, unregulated DC voltage with respect to GND, power feed to front panel pcb +24 volts DC, unregulated DC voltage with respect to GND, power feed to front panel pcb 24 volts DC, unregulated DC voltage with respect to GND, power feed to front panel pcb 24 volts DC, unregulated DC voltage with respect to GND, power feed to front panel pcb Negative weld output terminal; used for output voltage feedback Not Used Input Positive weld output terminal; used for output voltage feedback

Receptacle RC1

Pin 1

Type Output

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 RC2 1 2 3

Output Input

XMT 350 MPa

TM-231 242 Page 69

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

Section 9-32. Front Panel/Display Board PC3 Test Point Values (Continued)
Receptacle RC50 Pin A B C D E F G H I J K L M Type Output Input Output GND Input Output GND Output Output Input Chassis Input Input Value 23 volts AC RMS at 10 amps; 14pin remote accessory power Remote output enable; 0 volts AC = weld output off, 23 volts AC RMS = weld output on Output signal to remote command reference; +10 volts DC Remote command reference signal common Input signal from remote command; 0 to 10 volts DC, +13.5 volts DC when not connected to remote command from accessory Current feedback; 1 volt DC per 100 amperes of weld output 14pin remote accessory power return Voltage feedback; 1 volt DC per 10 volts DC of weld output 115 volts AC RMS at 2 amps; 14pin remote accessory power Remote output enable; 0 volts AC = weld output off, 115 volts AC RMS = weld output on Power source chassis Wirefeed command. 0 to +10 volts DC from synergic capable wire feeder Prior to MA370426A not used. Effective with MA370426A Remote Process Select. When connected to Remote Process Select capable single wirefeeder; Mig = 3.5 volts DC, Pulse = 2.5 volts DC. When connected 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 Wirefeed speed common

Input

9-33. Checking Unit Output After Servicing

1 Weld Output Terminals Check open-circuit voltage between terminals according to Section 9-18 (voltage V-14) If correct voltage is not present, repeat troubleshooting procedures. Reinstall cover and side panels if removed.

803 691-C

TM-231 242 Page 70

XMT 350 MPa

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

9-34. Enabling Low Open Circuit Voltage Welding Modes (Optional) Effective W/MA100311A
!
Disconnect and lockout/tagout input power before removing cover.

Follow this procedure to configure the unit for low open circuit voltage (OCV) operation in Stick and Scratch Start Tig modes. OCV is reduced to about 15 volts DC. 1 1 Front Panel And Display Board PC3

Remove wrapper. Place switch position 1 in the Closed position by pressing actuator toward board. Reinstall wrapper.

907 161-A / 242 727-C

XMT 350 MPa

TM-231 242 Page 71

SECTION 10 MAINTENANCE
10-1. Routine Maintenance
!
Disconnect power before maintaining.

. Maintain more often

during severe conditions.

3 Months
Replace Damaged Or Unreadable Labels Repair Or Replace Cracked Cables Replace Cracked Torch Body

Repair Or Replace Cracked Cables And Cords

Clean And Tighten Weld Connections

6 Months
Blow Out Inside

10-2. Blowing Out Inside Of Unit

!
Do not remove case when blowing out inside of unit.

To blow out unit, direct airflow through front and back louvers as shown.

Blowing Out Unit 201001

TM-231 242 Page 72

XMT 350 MPa

10-3. Removing Fan Motor

!
Significant DC voltage can remain on capacitors after unit is Off. Always check capacitors according to Section 9-2 to be sure they have discharged before working on unit. may not reflect actual unit. Mounting Unit Foot Base Fan Motor Louver

. Drawing is representative and

1 2 3 4 1

Remove wrapper from unit. Place unit upside down on secure work area as shown. Remove mounting unit feet. Lift off base. 2 Remove louver from front panel assembly. Remove bolts (2) securing fan assembly. Disconnect fan motor plug and remove fan from unit. 3 Reverse steps to replace fan motor in unit.

Tools Needed: 1/2, 9/16 in. 5/16 in.

805 299-A

XMT 350 Auto Line

TM-2247 Page 73

Notes

TM-231 242 Page 74

XMT 350 MPa

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 circuit
inside machine case or contact distributor for more information. The following is a list of all diagrams for models covered by this manual.

Model XMT 350 MPa (208 575 Volt Models)

Serial Or Style Number LJ410832A thru MA370425A MA370426A thru MB380678A MB380679A thru MB520505A MB520506A and following

Circuit Diagram 231 442-B 249 903-A 254 090-A 256 234-A 220 469-B 242 816-D 225 066-C 246 338-A 225 684-E 244 285-B

Wiring Diagram 231 458-A 231 458-A 256 241-A 256 241-A

Circuit Board PC1 (Control W/Program)

LJ410832A thru MA070469A MA070470A and following

Circuit Board PC2 (Power Interconnect)

LJ410832A thru MB510231A MB510232A and following

Circuit Board PC3 (Front Panel/Display) Not included in this manual

LJ410832A thru MA060330P MA060331P and following

XMT 350 MPa

TM-231 242 Page 75

Figure 11-1. Circuit for XMT 350 MPa (208 575 Volt) Eff. w/LJ410832A Thru MA3704525A
TM-231 242 Page 76 XMT 350 MPa

231 442-B

XMT 350 MPa

TM-231 242 Page 77

Figure 11-2. Circuit for XMT 350 MPa (208 575 Volt) Eff. w/MA370426A Thru MB380678A
TM-231 242 Page 78 XMT 350 MPa

249 903-A

XMT 350 MPa

TM-231 242 Page 79

Figure 11-3. Circuit for XMT 350 MPa (208 575 Volt) Eff. w/MB380679A Thru MB520505A
TM-231 242 Page 80 XMT 350 MPa

254 090-A

XMT 350 MPa

TM-231 242 Page 81

Figure 11-4. Circuit for XMT 350 MPa (208 575 Volt) Eff. w/MB520506A And Following
TM-231 242 Page 82 XMT 350 MPa

256 234-A

XMT 350 MPa

TM-231 242 Page 83

Figure 11-5. Wiring Diagram for XMT 350 MPa (208 - 575 Volt) Eff. w/LJ410832A Thru MB380678A (1 of 2)
TM-231 242 Page 84 XMT 350 MPa

231 458-A

XMT 350 MPa

TM-231 242 Page 85

Figure 11-6. Wiring Diagram for XMT 350 MPa (208 575 Volt) Eff. w/LJ410832A Thru MB380678A (2 of 2)
TM-231 242 Page 86 XMT 350 MPa

231 458-A

XMT 350 MPa

TM-231 242 Page 87

Figure 11-7. Wiring Diagram for XMT 350 MPa (208 - 575 Volt) Eff. w/MB380679A And Following (1 of 2)
TM-231 242 Page 88 XMT 350 MPa

256 241-A

XMT 350 MPa

TM-231 242 Page 89

Figure 11-8. Wiring Diagram for XMT 350 MPa (208 575 Volt) Eff. w/MB380679A And Following (2 of 2)
TM-231 242 Page 90 XMT 350 MPa

256 241-A

XMT 350 MPa

TM-231 242 Page 91

Notes

Start Your Professional Welding Career Now!

TM-231 242 Page 92

400 Trade Square East, Troy, Ohio 45373 1-800-332-9448 www.welding.org

Over 80,000 trained since 1930!

XMT 350 MPa

TM-231 242G Processes

Multiprocess Welding

201201

Eff w/Serial Number LJ410832A

Description

Arc Welding Power Source

XMT 350 MPa Auto-Line

Eff w/LJ410832A And Following

For OM-231 242 Revisions C Thru L

Visit our website at

www.MillerWelds.com

16 33 26 17 25 29 27 79 15 10 23 28 20 38 39 8 24 7 57 58 78 56 77 76 59 51 MOD 2 75 74 61 64 62 63 64 55 54 53 65 49 46 48 52 60 50 MOD 1 48 6 40 41 42 43 44 45 20 47 37 22 18 19 30 31 32 12 13 14

TM-231 242 Page 94 34 35 9 21 36

11

Figure 12-1. Parts Assembly

73

72

71 70

69

66

67

SECTION 12 PARTS LIST FOR LJ410832A AND FOLLOWING

XMT 350 MPa

Ref. 804 771-D

68

Eff w/LJ410832A AND FOLLOWING

Item No. Dia. Mkgs. Part No. Description Figure 12-1. Parts Assembly . . . 1 . . . . . . . . . . . . . . . 216 034 . . . . . . . . . . . . . . . . . . . . . 175 256 . . . . . . . . . . . . . . . . . . . . . 178 551 . . . 2 . . . . . . . . . . . . . . . 134 327 . . . 3 . . . . . . . . . . . . . . . 138 442 . . . 4 . . . . . . . . . . . . . . . 195 585 . . . 5 . . . . . . . . . . . . . . . 135 483 . . . 6 . . . . . . . . . . . . . . . 225 097 . . . 7 . . . . . . . . . . . . . . . 211 503 . . . 8 . . . . . . . . . . . . . . +212 207 . . . 9 . . . . . . . . . . . . . . . 196 355 . . . 10 . . . . . . . . . . . . . . . 199 840 . . . 11 . . . . R3/C4 . . . . 196 518 . . . 11 . . . . R3/C4 . . . . 233 052 . . . 12 . . . . . SR1 . . . . . 201 530 . . . 13 . . . . D1,D2 . . . . 201 531 . . . 14 . . . . . RT1 . . . . . 199 798 . . . 15 . . . . . CR1 . . . . . 198 549 . . . 16 . . . . . . . . . . . . . . . 227 127 . . . 17 . . . . . . . . . . . . . . . 227 746 . . . 18 . . . . . . . . . . . . . . . 010 546 . . . 19 . . . . . . L4 . . . . . . 218 020 . . . 20 . . . . . . . . . . . . . . . 179 276 . . . 21 . . . . . . . . . . . . . . . 170 647 . . . 22 . . . . . . L3 . . . . . . 212 150 . . . 23 . . . . . . T1 . . . . . . 212 132 . . . 24 . . . . . . L1 . . . . . . 212 091 . . . 25 . . . . . . . . . . . . . . . 083 147 . . . 26 . . . . . PC1 . . . . . 224 098 . . . 26 . . . . . PC1 . . . . . 242 812 . . . 26 . . . . . PC1 . . . 224 649 . . . 26 . . . . . PC1 . . . 242 341 . . . . . . . . . . . . . . . . . . . . . 216 113 . . . . . . . . . . PLG1 . . . . 115 091 . . . . . . . . . . PLG2 . . . . 201 665 . . . . . . . . . . PLG3 . . . . 131 056 . . . . . . . . . . PLG5 . . . . 131 204 . . . . . . . . . . PLG7 . . . . 131 054 . . . . . . . . . . PLG8 . . . . 131 054 . . . . . . . . . . PLG9 . . . . 115 093 . . . . . . . . . . PLG10 . . . . 115 094 . . . . . . . . . . PLG11 . . . . 115 094 . . . . . . . . . . PLG12 . . . . 115 092 . . . 27 . . . . . . . . . . . . . . . 212 072 . . . 28 . . . . C12,13 . . . . 219 930 . . . . . . . . . . . RC2 . . . 604 176 . . . 29 . . . . . CB2 . . . . . 083 432 . . . 30 . . . . . CB1 . . . . . 089 807 . . . 30 . . . . . CB1 . . . 083 432 . . . 31 . . . . . . . . . . . . . . +212 071 . . . 31 . . . . . . . . . . . . +212 202 . . . 32 . . . . . . . . . . . . . . . 126 026 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. Wrapper (Includes Insulators and Safety Labels) . . . . . . . . . . . . . . . . . . . 1 Insulator, Side Rh (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Insulator, Side (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Label, Warning General Precautionary Static & Wire Feed . . . . . . . . . . . 2 Label, Caution Falling Equip Can Cause Injury . . . . . . . . . . . . . . . . . . . . . 2 Handle, Rubberized Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Label, Important Remove These Two Handle Screws . . . . . . . . . . . . . . . 2 Heat Sink, Lh Rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Insulator, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Windtunnel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Resistor/Capacitor (Prior to MA020694A) . . . . . . . . . . . . . . . . . . . . . . . . . 1 Resistor/Capacitor (Eff w/MA020694A) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Kit, Diode Fast Recovery Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Thermistor, NTC 30K Ohm @ 25 Deg C 18In Lead . . . . . . . . . . . . . . . . . 1 Relay, Encl 24VDC Spst 35A/300VAC 4Pin Flange Mtg . . . . . . . . . . . . . 1 Label, Warning Electric Shock/Exploding Parts . . . . . . . . . . . . . . . . . . . . . 1 Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Bushing, Snap-In Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . . . 1 Inductor, Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Bushing, Snap-In Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . . . . . . . . 3 Bushing, Snap-In Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . . 1 Inductor, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 XFMR, HF Litz/Litz W/Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . . . 4 Circuit Card Assy, Control W/Program (Prior to MA070470A) . . . . . . . . 1 Circuit Card Assy, Control W/Program (Eff w/MA070470A) . . . . . . . . . . 1 Circuit Card Assy, Control/Aux Power W/Program (Prior to MA070470A)1 Circuit Card Assy, Control/Aux Power W/Program (Eff w/MA070470A) 1 Stand-Off Support, PC Card .187 Dia W/P&l .375 . . . . . . . . . . . . . . . . . . 2 Housing Plug+Pins (Service Kit) RC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Housing Plug+Pins (Service Kit) RC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Housing Plug+Pins (Service Kit) RC3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Housing Plug+Pins (Service Kit) RC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Housing Plug+Pins (Service Kit) RC7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Housing Plug+Pins (Service Kit) RC8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Housing Plug+Pins (Service Kit) RC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Housing Plug+Pins (Service Kit) RC10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Housing Plug+Pins (Service Kit) RC11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Housing Plug+Pins (Service Kit) RC12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Bracket, Mtg Capacitor/PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Kit, Capacitor Elctlt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Rcpt, Str Dx Grd 2P3W 15A 125V *515R . . . . . . . . . . . . . . . . . . . . . . . . 1 Supplementary Protector, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . 1 Supplementary Protector, Man Reset 1P 2.5A 250VAC Frict . . . . . . . . . 1 Supplementary Protector, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . 1 Panel, Rear Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Label, Warning Electric Shock Can Kill Significant . . . . . . . . . . . . . . . . . . 1 Quantity

+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 Option BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
XMT 350 MPa TM-231 242 Page 95

Eff w/LJ410832A AND FOLLOWING

Item No. Dia. Mkgs. Part No. Description Figure 12-1. Parts Assembly (Continued) . . . 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 DB9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 60 . . . . . . . . . . . . . . . 230 944 . . Cover, Enclosure Connector DB9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 +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 Option BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-231 242 Page 96 XMT 350 MPa

Quantity

Eff w/LJ410832A AND FOLLOWING

Item No. Dia. Mkgs. Part No. Description Figure 12-1. Parts Assembly (Continued) . . . 62 . . . . . . . . . . . . . . . 176 226 . . Insulator, Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 . . . . . FM1 . . . . . 196 313 . . Fan, Muffin 115V 50/60Hz 3000 RPM 6.378 Mtg Holes . . . . . . . . . . . . . . . . . . . . . . . . PLG16 . . . . 131 054 . . Housing Plug+Pins (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC16 . . . . 135 635 . . Housing Plug+Pins (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 . . . . . . . . . . . . . . . 208 967 . . Rcpt Assy, Tw Lk Insul Fem (Dinse Type) 50/70 Series (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . 208 968 . . . . Rcpt, Tw Lk Insul W/O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 712 . . . . Insulator, Bulkhead Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 713 . . . . Insulator, Bulkhead Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 714 . . . . Washer, Tooth 22Mmid X 31.5Mmod 1.310-1Mmt Intern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 717 . . . . Nut, M20-1.5 1.00Hex .19H Brs Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 718 . . . . O-Ring, 0.989 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 228 . . . . O-Ring, 0.739 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 548 . . . . Terminal, Connection Friction (Eff w/MB520506A) . . . . . . . . . . . . . . . . . . . 64 . . . . . . . . . . . . 218 183 . . Rcpt Assy, Tw Lk Insul Fem(Tweco Type) (FacOp) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 473 . . . . Rcpt, Twist Lock Tweco Style (Female) Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 712 . . . . Insulator, Bulkhead Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 713 . . . . Insulator, Bulkhead Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 714 . . . . Washer, Tooth 22Mmid X 31.5Mmod 1.310-1Mmt Intern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 717 . . . . Nut, M20-1.5 1.00Hex .19H Brs Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 718 . . . . O-Ring, 0.989 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 228 . . . . O-Ring, 0.739 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 548 . . . . Terminal, Connection Friction (Eff w/MB520506A) . . . . . . . . . . . . . . . . . . . 65 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Power (Order by Model and Serial Number) . . . . . . . . . . . . . . . . 66 . . . . . . . . . . . . . . . 231 473 . . Label, Process (Prior to LJ410832A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 . . . . . . . . . . . . . . . 240 959 . . Label, Process (Eff w/LJ410832A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 . . . . . . . . . . . . . . . 218 041 . . Door, W/Quick Access Ball Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 . . . . . . . . . . . . . . . 175 138 . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 . . . . . . . . . . . . . . . . . . . . . . . . . . Label, (Order by Model and Serial Number) . . . . . . . . . . . . . . . . . . . . . . . . . . 70 . . . . . . . . . . . . . . . 174 991 . . Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip.21 . . . . . . . . . . . . . . . . . . 71 . . . . . . . . . . . . . . . 231 468 . . Nut, 37532 .56Hex .22H Brs Conical Knurl . . . . . . . . . . . . . . . . . . . . . . . . . . 72 . . . . . . . . . . . . . . . 231 469 . . Nut, 50028 .69Hex .28H Brs Conical Knurl . . . . . . . . . . . . . . . . . . . . . . . . . . 73 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Connection (Order by Model and Serial Number) . . . . . . . . . . . 74 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate (Order by Model and Serial Number) . . . . . . . . . . . . . . . . . . . . . . 75 . . . . . . . . . . . . . . . 216 112 . . Fastener, Panel Receptacle Quick Access . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 . . . . . C6,7 . . . . . 214 749 . . Capacitor Assy, W/Plug And Leads (Voltage Feedback) . . . . . . . . . . . . . . . . 77 . . . . . . . . . . . . . . . 226 590 . . Panel, Front Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 . . . . . . . . . . . . . . . 231 470 . . Nut, Adapter Encoder Shaft Mtg 37532 To 50028 . . . . . . . . . . . . . . . . . . . 79 . . . . . . L8 . . . . . . 241 027 . . Core, Toroidal (Eff w/MB380679A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +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 Option BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 Quantity

XMT 350 MPa

TM-231 242 Page 97

Miller Electric Mfg. Co.

An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International HeadquartersUSA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com

ORIGINAL INSTRUCTIONS PRINTED IN USA

2012 Miller Electric Mfg. Co.