Miller Electric 460Volt Specifiche

CC/CV and CC ModelsTM-2208E July 2000Eff. w/Serial Number KG049063ProcessesDescriptionMultiprocess WeldingArc Welding Power SourceEX300(230/460 and 4

TM-2208 Page 8 XMT 3043-6. Connecting Input PowerCheck input voltage available atsite.. The Auto-Link circuitry in thisunit automatically links thepow

Eff w/KK104771 And FollowingTM-2208 Page 98 XMT 304DescriptionPartNo.Dia.Mkgs.ItemNo. Figure 11-1. Parts Assembly (Continued)Quantity39 PC2 C

Eff w/KK104771 And FollowingTM-2208 Page 99XMT 304Notes

Eff w/KK104771 And FollowingTM-2208 Page 100 XMT 304Notes

PRINTED IN USA  1998 Miller Electric Mfg. Co.Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USAInte

TM-2208 Page 9XMT 304Notes

TM-2208 Page 10 XMT 304SECTION 4 – OPERATION4-1. Front Panel Controls For CC/CV Model 1 Power Switch. The fan motor is thermostaticallycontrolled and

TM-2208 Page 11XMT 3044-2. Meter Functions For CC/CV ModelThe meters display the actual weld output values for approximately three secondsafter the ar

TM-2208 Page 12 XMT 3044-4. Front Panel Controls For CC ModelRef. ST-175 50023 4517 61 Power Switch. The fan motor is thermostaticallycontrolled and o

TM-2208 Page 13XMT 3044-5. Meter Functions For CC ModelThe meters display the actual weld output values for approximately three secondsafter the arc i

TM-2208 Page 14 XMT 304SECTION 5 – THEORY OF OPERATION. Theory of Operation is shown forthe 230/460 volt models. Theoryfor other models is similar.1 P

TM-2208 Page 15XMT 30415 Voltage/Amperage AdjustmentControl R2 (CC/CV Models) OrAmperage Adjustment ControlR2 (CC Models)Selects weld output voltage o

TM-2208 Page 16 XMT 304SECTION 6 – PRE-POWER CHECKLIST6-1. Checking Unit Before Applying Power. See Section 7-4 for test points and values and Section

TM-2208 Page 17XMT 3046-3. Input Rectifier SR1ST-801 550 / Ref. SD-183 484Y Read and follow safetyinformation in Section 6-1before proceeding.. Resi

TABLE OF CONTENTSSECTION 1 – SAFETY PRECAUTIONS FOR SERVICING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage

TM-2208 Page 18 XMT 3046-5. IGBT Modules PM1, PM2Y Read and follow safetyinformation in Section 6-1before proceeding.. It is not necessary to remove

TM-2208 Page 19XMT 3046-6. Diodes D1, D2, D3, D4ST-801 550 / 195 587Y Read and follow safetyinformation in Section 6-1before proceeding.1 Check D1 a

TM-2208 Page 20 XMT 3046-7. Contactors W1, W2 (230/460 V Models Only)ST-801 550 / 195 587Y Read and follow safetyinformation in Section 6-1before pr

TM-2208 Page 21XMT 304SECTION 7 – TROUBLESHOOTING7-1. Troubleshooting Table. See Section 7-4 and Section 7-6 for test points andvalues and Section 10

TM-2208 Page 22 XMT 304Trouble RemedyLimited output and low open-circuitvoltage.Follow pre-power checklist (see Section 6).Check incoming power for co

TM-2208 Page 23XMT 3047-2. Voltmeter/Ammeter Help Displays Prior to KG177169*1 Help 1 DisplayIndicates a malfunction in the pri-mary power circuit. If

TM-2208 Page 24 XMT 3047-3. Voltmeter/Ammeter Help Displays Effective with KG177169*1AV2AV3AVHE.L P–0HE.L P–1HE.L P–24AVHE.L P–35AVHE.L P–4. *Effectiv

TM-2208 Page 25XMT 304Notes

TM-2208 Page 26 XMT 304V11V127-4. Troubleshooting Circuit Diagram For 230/460 Volt Models Prior To Serial No. KK104771Y Discharge input capacitors acc

TM-2208 Page 27XMT 304Resistance Valuesa) Tolerance – ±10% unless specifiedb) Turn Off unit and disconnect input powerbefore checking resistanceR1 thr

TM-2208 Page 1XMT 304SECTION 1 – SAFETY PRECAUTIONS FOR SERVICINGsafety_stm1 4/951-1. Symbol UsageMeans Warning! Watch Out! There are possible hazards

TM-2208 Page 28 XMT 304V10V117-5. Troubleshooting Circuit Diagram For 230/460 Volt ModelsWith Serial Nos. Following KK104771Y Discharge input capacito

TM-2208 Page 29XMT 304Resistance Valuesa) Tolerance – ±10% unless specifiedb) Turn Off unit and disconnect input powerbefore checking resistanceR1 thr

TM-2208 Page 30 XMT 3047-6. Troubleshooting Circuit Diagram for 460/575 Volt Models Prior To Serial No. KK104771Y Discharge input capacitors according

TM-2208 Page 31XMT 304Resistance Valuesa) Tolerance – ±10% unless specifiedb) Turn Off unit and disconnect input powerbefore checking resistanceR1 thr

TM-2208 Page 32 XMT 3047-7. Troubleshooting Circuit Diagram for 460/575 Volt Models With Serial Nos. Following KK104771Y Discharge input capacitors ac

TM-2208 Page 33XMT 304Resistance Valuesa) Tolerance – ±10% unless specifiedb) Turn Off unit and disconnect input powerbefore checking resistanceR1 thr

TM-2208 Page 34 XMT 3047-8. Waveforms For Sections 7-4 Thru 7-7Test Equipment Needed:10 µs 20 VA. CC Or CV Mode, DC Open-Circuit Voltage10 µs 20 VB.

TM-2208 Page 35XMT 3047-9. Control Board PC1 Testing Information (All Models – Use with Section 7-10)ST-801 550 / 193 753Y Discharge input capacitorsa

TM-2208 Page 36 XMT 3047-10. Control Board PC1 Test Point Values (All Models)a) Tolerance – ±10% unless specifiedb) Reference – to circuit common(lead

TM-2208 Page 37XMT 304Receptacle ValuePinRC2 8 –15 volts dc output (Prior to KK104771)Not used (Effective w/KK104771)9 +1 volts dc input per 100 amper

TM-2208 Page 2 XMT 304FALLING EQUIPMENT can causeserious personal injury and equipmentdamage.1. Use lifting eye to lift unit only, NOT running gear,ga

TM-2208 Page 38 XMT 304Receptacle ValuePinRC8 1 +28 volts dc output with respect to pin RC8-2 when fan is turned On2 –28 volts dc output with respect

TM-2208 Page 39XMT 3047-11. Display Board PC3 Testing Information (All Models – Use with Section 7-12)ST- 801 550 / 190 701Y Discharge input capacitor

TM-2208 Page 40 XMT 3047-12. Display Board PC3 Test Point Values (All Models)PC3 Voltage Readingsa) Tolerance – ±10% unless specifiedb) Reference – to

TM-2208 Page 41XMT 304Receptacle ValuePinRC2 1 Prior to Serial No. KG177169, voltage feedback input with respect to pin RC2-6, same as positive (+)wel

TM-2208 Page 42 XMT 3047-13. Interconnecting Board PC2 Testing Information (All Models)ST-801 550 / 195 587Y Discharge input capacitorsaccording to Se

TM-2208 Page 43XMT 304SECTION 8 – MAINTENANCE8-1. Routine MaintenanceY Disconnect power before maintaining.. Maintain more oftenduring severe conditio

TM-2208 Page 44 XMT 304ST-801 550Y Significant DC voltage canremain on capacitors afterunit is Off. Always check ca-pacitors as shown to be surethey h

TM-2208 Page 45XMT 3048-4. Checking Bus Voltage ImbalanceCheck for a bus voltage imbalance whenever any of the following components arereplaced: capac

TM-2208 Page 46 XMT 304SECTION 9 – ELECTRICAL DIAGRAMS. The circuits in this manual can be used for troubleshooting, but there might be minor circuit

TM-2208 Page 47XMT 304Model Wiring DiagramCircuit DiagramSerial Or Style NumberCircuit Board PC3(All CC Models)KH353059 thru KH526179 183 324-A♦♦KH526

TM-2208 Page 3XMT 304SECTION 2 – INTRODUCTION2-1. SpecificationsVoltage Amperage Max. Open-RMS Amps Input at Rated LoadOutput, 60 Hz 3-Phase at NEMA

TM-2208 Page 48 XMT 304SC-175 014-A. *Thru KG177341 w/auxiliary powerFigure 9-1. Circuit for XMT 304 (230/460 V) Eff. w/KG049063 – KG177168*

TM-2208 Page 49XMT 304SC-181 837-B. *Effective w/KG177342 w/auxiliary powerFigure 9-2. Circuit for XMT 304 (230/460 V) Eff. w/KG177169* Thru KK104770

TM-2208 Page 50 XMT 304194 588Figure 9-3. Circuit for XMT 304 (230/460 V) Eff. w/KK104771 Thru KK266149

TM-2208 Page 51XMT 304197 550Figure 9-4. Circuit for XMT 304 (230/460 V) Eff. w/KK266150

TM-2208 Page 52 XMT 304Notes

TM-2208 Page 53XMT 304SC-180 958-CFigure 9-5. Circuit for XMT 304 (460/575 V) Eff. w/KG145520 Thru KK104770

TM-2208 Page 54 XMT 304194 589Figure 9-6. Circuit for XMT 304 (460/575 V) Eff. w/KK104771 Thru KK266149

TM-2208 Page 55XMT 304197 553Figure 9-7. Circuit for XMT 304 (460/575 V) Eff. w/KK266150

TM-2208 Page 56 XMT 304Figure 9-8. Diagram for XMT 304 (230/460 V) Eff. w/KK104771

TM-2208 Page 57XMT 304195 876

TM-2208 Page 4 XMT 3042-3. Volt-Ampere Curvesva_curve1 4/95 – SA-178 652 / SA-178 653Volt-ampere curves show mini-mum and maximum voltage andamperage

TM-2208 Page 58 XMT 304Figure 9-9. Diagram for XMT 304 (460/575 V) Eff. w/KK104770

TM-2208 Page 59XMT 304195 877

TM-2208 Page 60 XMT 304Figure 9-10. Circuit for PC1 (230/460 V) Eff. w/KH526181 (CC) or KH523149 (CC/CV) Thru KK104770 (Part 1 of 3)

TM-2208 Page 61XMT 304185 507-A (1 of 3)

TM-2208 Page 62 XMT 304Figure 9-11. Circuit for PC1 (230/460 V) Eff. w/KH526181 (CC) or KH523149 (CC/CV) Thru KK104770 (Part 2 of 3)

TM-2208 Page 63XMT 304185 507-A (2 of 3)

TM-2208 Page 64 XMT 304Figure 9-12. Circuit for PC1 (230/460 V) Eff. w/KH526181 (CC) or KH523149 (CC/CV) Thru KK104770 (Part 3 of 3)

TM-2208 Page 65XMT 304185 507-A (3 of 3)

TM-2208 Page 66 XMT 304Figure 9-13. Circuit for PC1 (230/460 V) Eff. w/KK104771 (Part 1 of 3)

TM-2208 Page 67XMT 304193 755 (1 of 3)

TM-2208 Page 5XMT 304SECTION 3 – INSTALLATION3-1. Selecting a Locationloc_2 3/96 - Ref. ST-151 556 / ST-801 1921 Lifting HandlesUse handles to lift un

TM-2208 Page 68 XMT 304Figure 9-14. Circuit for PC1 (230/460 V) Eff. w/KK104771 (Part 2 of 3)

TM-2208 Page 69XMT 304193 755 (2 of 3)

TM-2208 Page 70 XMT 304Figure 9-15. Circuit for PC1 (230/460 V) Eff. w/KK104771 (Part 3 of 3)

TM-2208 Page 71XMT 304193 755 (3 of 3)

TM-2208 Page 72 XMT 304Figure 9-16. Circuit for PC1 (460/575 V) Eff. w/KH499631 Thru KK104770 (Part 1 of 3)

TM-2208 Page 73XMT 304188 657-A (1 of 3)

TM-2208 Page 74 XMT 304Figure 9-17. Circuit for PC1 (460/575 V) Eff. w/KH499631 Thru KK104770 (Part 2 of 3)

TM-2208 Page 75XMT 304188 657-A (2 of 3)

TM-2208 Page 76 XMT 304Figure 9-18. Circuit for PC1 (460/575 V) Eff. w/KH499631 Thru KK104770 (Part 3 of 3)

TM-2208 Page 77XMT 304188 657-A (3 of 3)

TM-2208 Page 6 XMT 3043-2. Weld Output Receptacles And Selecting Cable SizesTotal Cable (Copper) Length In Weld Circuit Not Exceeding100 ft (30 m) Or

TM-2208 Page 78 XMT 304Figure 9-19. Circuit for PC1 (460/575 V) Eff. w/KK104771 (Part 1 of 3)

TM-2208 Page 79XMT 304193 761 (1 of 3)

TM-2208 Page 80 XMT 304Figure 9-20. Circuit for PC1 (460/575 V) Eff. w/KK104771 (Part 2 of 3)

TM-2208 Page 81XMT 304193 761 (2 of 3)

TM-2208 Page 82 XMT 304Figure 9-21. Circuit for PC1 (460/575 V) Eff. w/KK104771 (Part 3 of 3)

TM-2208 Page 83XMT 304193 761 (3 of 3)

TM-2208 Page 84 XMT 304Figure 9-22. Circuit for PC3 (CC) Eff. w/KJ188992

TM-2208 Page 85XMT 304190 706

TM-2208 Page 86 XMT 304Figure 9-23. Circuit for PC3 (CC/CV) Eff. w/KJ188992

TM-2208 Page 87XMT 304190 703

TM-2208 Page 7XMT 304ST-801 245-A1 115 V 10 A AC ReceptaclePower is shared between duplexreceptacle and Remote 14 recep-tacle (see Section 3-3).2 Circ

TM-2208 Page 88 XMT 304195 589Figure 9-24. Circuit for PC2 Eff. w/KK266150188 015Figure 9-25. Circuit for PC4, PC5 Eff. w/KH450176

Visit our website atwww.Miller-Welds.comEff w/KG049063 Thru KK104770For OM-2208 (175 493) Revisions * Thru JXMT 304(230/460 And460/575 Volt Models)RTM

TM-2208 Page 90 XMT 304SECTION 10 – PARTS LIST FOR KG049063 THRU KK104770ST-801 428-B. Hardware is common andnot available unless listed.1234323334353

Eff w/KG049063 THRU KK104770TM-2208 Page 91XMT 304DescriptionPartNo.Dia.Mkgs.ItemNo. Figure 10-1. Parts AssemblyQuantity1 +175 148 WRAPPER 1.

Eff w/KG049063 THRU KK104770TM-2208 Page 92 XMT 304DescriptionPartNo.Dia.Mkgs.ItemNo. Figure 10-1. Parts Assembly (Continued)Quantity30 T2 17

Eff w/KG049063 THRU KK104770TM-2208 Page 93XMT 304DescriptionPartNo.Dia.Mkgs.ItemNo. Figure 10-1. Parts Assembly (Continued)Quantity54 PC3 19

OM-2223 Page 94Notes

Visit our website atwww.Miller-Welds.comEff w/KK104771 And FollowingFor OM-2208 (175 493) Revision K And FollowingXMT 304(230/460 And460/575 Volt Mode

TM-2208 Page 96 XMT 304SECTION 11 – PARTS LIST FOR KK104771 AND FOLLOWINGST-801 428-C. Hardware is common andnot available unless listed.1234323334353

Eff w/KK104771 And FollowingTM-2208 Page 97XMT 304DescriptionPartNo.Dia.Mkgs.ItemNo. Figure 11-1 . Parts AssemblyQuantity1 +175 148 WRAPPER 1