Miller XMT 304 User Manual - Free PDF Download

Page 2 - From Miller to You

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearestdistributor or service agency call ...

Page 3 - TABLE OF CONTENTS

TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1...

Page 4 - DECLARATION OF CONFORMITY; declares that the

DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions ofthe stated Council Directive(s) and Stand...

Page 5 - SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.

OM-233 045 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 7 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, ifnot avoided, will re...

Page 6 - ARC RAYS can burn eyes and skin.; BUILDUP OF GAS can injure or kill.

OM-233 045 Page 2 Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at thearc to remove we...

Page 7 - Additional Symbols For Installation, Operation, And Maintenance

OM-233 045 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system isproperly siz...

Page 9 - SECTION 2 −; CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION; Symboles utilisés; Dangers relatifs au soudage à l’arc

OM-233 045 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 7 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relativesaux précautions de sécurité et au mode opératoire. 2-1. Symboles utilisés D...

Page 11 - LE BRUIT peut endommager l’ouïe.

OM-233 045 Page 7 LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou même la mort. D Fermer l’alimentation du gaz comprimé en casde non utilisation. D Veiller toujours à bien aérer les espaces confi-nés ou se servir d’un respirateur d’adductiond’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUE...

Page 12 - LIRE LES INSTRUCTIONS.; Proposition californienne 65 Avertissements

OM-233 045 Page 8 Les PIÈCES MOBILES peuventcauser des blessures. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincementtels que des rouleaux de commande. LES FILS DE SOUDAGE peuventprovoquer des blessures. D Ne pas appuyer sur la gâchette avant d’enavoir reçu l’inst...

Page 15 - SECTION 3 − DEFINITIONS; Manufacturer ’s Warning Label Definitions

OM-233 045 Page 11 SECTION 3 − DEFINITIONS 3-1. Manufacturer ’s Warning Label Definitions Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk 179310-B Warning! Watch Out! There are possiblehazards as shown...

Page 17 - Hz

OM-233 045 Page 13 3-2. WEEE Label Do not discard this product withgeneral waste. Reuse or recycle Waste Electricaland Electronic Equipment (WEEE)by disposing at a designated collec-tion facility. Contact your local recycling officeor your local distributor for furtherinformation. 3-3. Symbols And D...

Page 18 - SECTION 4 − INSTALLATION; Important Information Regarding CE Products (Sold Within The EU); Serial Number And Rating Label Location

OM-233 045 Page 14 SECTION 4 − INSTALLATION 4-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) ! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This eq...

Page 19 - Duty Cycle And Overheating

OM-233 045 Page 15 6 Minutes Welding 4 Minutes Resting 4-4. Duty Cycle And Overheating Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. If unit overheats, output stops, aHelp message is displayed (seeSection 6-3), and cooling fan runs.Wait fifteen minutes ...

Page 20 - Dimensions And Weight; Selecting a Location

OM-233 045 Page 16 4-6. Dimensions And Weight Hole Layout Dimensions 24 in. (610 mm) 17 in. (432 mm) 12-1/2 in. (318 mm) 804 801-A A D C B E G F A 11-3/4 in. (298 mm) B 1-11/16 in. (42 mm) C 15-3/4 in. (400 mm) D 19-3/32 in. (485 mm) E 8-11/16 in. (221 mm) F 1-17/32 in. (39 mm) G 1/4-20 UNC -2B thre...

Page 21 - Weld Output Terminals And Selecting Cable Sizes

OM-233 045 Page 17 4-8. Weld Output Terminals 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 is100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200...

Page 22 - Remote 14 Receptacle Information

OM-233 045 Page 18 4-9. Remote 14 Receptacle Information ST-801 192 A J B K I C L N H D M G E F Socket* Socket Information 24 VOLTS AC A 24 volts AC. Protected by supplementary protect-or CB2. B Contact closure to A completes 24 volts AC con-tactor control circuit. 115 VOLTS AC I 115 volts AC. Prote...

Page 23 - Notes

OM-233 045 Page 19 4-11. Electrical Service Guide Elec Serv 2011− NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply ofinput power at rated frequency (+ 10%) and voltage (+ 10%). Phase to ground voltage shall not exceed +10% of...

Page 25 - SECTION 5 − OPERATION; Front Panel Controls

OM-233 045 Page 21 SECTION 5 − OPERATION 5-1. Front Panel Controls 1 Power On/Off Switch . The fan motor is thermostaticallycontrolled and only runs when cooling isneeded. 2 Voltmeter (see Section 5-2) 3 Ammeter (see Section 5-2) 4 Voltage/Amperage Adjustment Control 5 Mode Switch The Mode switch se...

Page 26 - Meter Functions; PPP

OM-233 045 Page 22 5-2. Meter Functions . The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle Scratch Start TIG (GTAW) Actual Volts (OCV) Preset Amps V A 80.0 85 Lift-Arc Trigger Hold TIG (GTAW) V A Blank Preset Amps 85...

Page 27 - Mode Switch Settings

OM-233 045 Page 23 5-3. Mode Switch Settings . The SMAW modes provide the Adaptive Hot Start ™ feature, which automatically increases the output amperage at the start of a weld should the start require it. This eliminates electrode sticking at arc start. Mode Output Control Scratch Start TIG (GTAW) ...

Page 28 - Lift-Arc Trigger Hold TIG

OM-233 045 Page 24 5-4. Lift-Arc Trigger Hold TIG 1 TIG Electrode 2 Workpiece . Procedure requires: Start sequence: • Touch tungsten electrode toworkpiece at weld start point. • Momentarily depress outputswitch. • Slowly lift electrode. An arc willform when electrode is lifted. • To stop welding, mo...

Page 29 - SECTION 6 − MAINTENANCE & TROUBLESHOOTING; Routine Maintenance

OM-233 045 Page 25 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance . Maintain more oftenduring severe conditions. ! Disconnect power before maintaining. 3 Months Replace Damaged Or Unreadable Labels Replace Cracked Torch Body Repair Or Replace Cracked Cables Repair Or Replace ...

Page 30 - Voltmeter/Ammeter Help Displays

OM-233 045 Page 26 6-3. Voltmeter/Ammeter Help Displays . All directions are in reference tothe front of the unit. All circuitryreferred to is located inside theunit. Help 0 Display Indicates a shorted thermistor RT2on the left side of the unit. If this dis-play is shown, contact a Factory Au-thoriz...

Page 32 - Troubleshooting

OM-233 045 Page 28 6-5. Troubleshooting Trouble Remedy No weld output; unit completely inop-erative. Place line disconnect switch in On position (see Section 4-12). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-12). Check for proper input power connections (se...

Page 33 - SECTION 7 − ELECTRICAL DIAGRAM; Figure 7-1. Circuit Diagram For Welding Power Source

OM-233 045 Page 29 SECTION 7 − ELECTRICAL DIAGRAM 239 356-B Figure 7-1. Circuit Diagram For Welding Power Source

Page 34 - SECTION 8 − PARTS LIST

OM-233 045 Page 30 SECTION 8 − PARTS LIST 801 605-J Figure 8.1. Parts Assembly

Page 37 - Start Your Professional

Notes Over 80,000 trained since 1930! 400 Trade Square East, Troy, Ohio 45373 1-800-332-9448 www.welding.org Start Your Professional Welding Career Now!

Page 38 - MATERIAL THICKNESS REFERENCE CHART

Notes 16 Gauge (.063 in.) 22 Gauge (.031 in.) 24 Gauge (.025 in.) 20 Gauge (.037 in.) 18 Gauge (.050 in.) 14 Gauge (.078 in.) 1/8 in. (.125 in.) 3/16 in. (.188 in.) 1/4 in. (.25 in.) 5/16 in. (.313 in.) 3/8 in. (.375 in.) 1/2 in. (.5 in.) MATERIAL THICKNESS REFERENCE CHART

Page 39 - (Equipment with a serial number preface of MC or newer)

Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 2012-01 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Con...

Page 40 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2012 Miller Electric Mfg. Co. 2012−01 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters−USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX:...