Miller XMT340 PDF

TM-180 670B September 2001
Eff. w/Serial Number KG139511
Processes
Multiprocess Welding
Description
Arc Welding Power Source
XMT 304
(400 Volt Models)
Visit our website at

www.MillerWelds.com
Declaration of Conformity For
European Community (CE) Products
Manufacturer’s Name: Miller Electric Mfg. Co.
Manufacturer’s Address: 1635 W. Spencer Street
Appleton, WI 54914 USA
Declares that the product: XMT 304

conforms to the following Directives and Standards:
Directives
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:

EN50199: December 1995
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1989
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:

Part 1: Principles, requirements and tests: IEC 664-1: 1992
European Contact: Danilo Fedolfi, Managing Director

MILLER Europe S.r.l.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
Telephone: 39(02)98290-1
Fax: 39(02)98281-552
dec_con1 10/95
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WARNING
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 This product, when used
1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 for welding or cutting,
produces fumes or
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 gases which contain
2-1. Manufacturer’s Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 chemicals known to the
2-2. Manufacturer’s Rating Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 State of California to
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 cause birth defects and,
in some cases, cancer.
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 (California Health &
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safety Code Section
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 25249.5 et seq.)
3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-5. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-6. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-7. 110 Volt AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-8. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-9. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-2. Meter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-3. Mode Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-4. Lift-Arc Trigger Hold TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 5 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 6 – EXPLANATION OF ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 7 – PRE-POWER CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7-1. Checking Unit Before Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7-2. Output Diodes D1, D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7-3. Input Rectifier SR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-4. Tank Capacitor C1 and Input Capacitors C3, C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-5. IGBT Modules PM1, PM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-6. Diodes D1, D2, D3, D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 8 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8-2. Voltmeter/Ammeter Help Displays Prior To Serial No. KG150087 . . . . . . . . . . . . . . . . . . . . . . 30
8-3. Voltmeter/Ammeter Help Displays Effective With KG150087 . . . . . . . . . . . . . . . . . . . . . . . . . 31
8-4. Troubleshooting Circuit Diagram For Welding Power Source Prior To KK104771 . . . . . . . . . 32
8-5. Troubleshooting Circuit Diagram For Welding Power Source Eff. With KK104771 . . . . . . . . 34
8-6. Waveforms For Sections 8-4 And 8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-7. Control Board PC1 Testing Information (All Models – Use With Section 8-8) . . . . . . . . . . . . . 37
8-8. Control Board PC1 Test Point Values (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-9. Display Board PC3 Testing Information (All Models – Use With Section 8-10) . . . . . . . . . . . 40
8-10. Display Board PC3 Test Point Values (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8-11. Interconnecting Board PC2 Testing Information (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 9 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9-3. Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9-4. Checking Bus Voltage Imbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SECTION 10 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SECTION 11 – PARTS LIST FOR KG139511 AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING
1-1. Symbol Usage
OM-180 670M - 1/00, safety_stm 5/97
Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible

Y Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. to avoid the hazards.
1-2. Servicing Hazards

Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see FLYING METAL can injure eyes.
the symbol, watch out, and follow the related instructions to
avoid the hazard. D Wear safety glasses with side shields or face
shield during servicing.
Y Only qualified persons should service, test, maintain, and re-
D Be careful not to short metal tools, parts, or
pair this unit.
wires together during testing and servicing.
Y During servicing, keep everybody, especially children, away.
HOT PARTS can cause severe burns.

ELECTRIC SHOCK can kill.
D Do not touch hot parts bare handed.
D Do not touch live electrical parts. D Allow cooling period before working on welding
gun or torch.
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 re-
ceptacle, or stop engine before servicing unless the procedure spe-
cifically requires an energized unit. EXPLODING PARTS can cause injury.
D Insulate yourself from ground by standing or working on dry insulat- D Failed parts can explode or cause other parts to
ing mats big enough to prevent contact with the ground. explode when power is applied to inverters.
D Always wear a face shield and long sleeves
D Do not leave live unit unattended. when servicing inverters.
D If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D When testing a live unit, use the one-hand method. Do not put both SHOCK HAZARD from testing.
hands inside unit. Keep one hand free.
D Turn Off welding power source and wire feeder
D Disconnect input power conductors from deenergized supply line
or stop engine before making or changing me-
BEFORE moving a welding power source.
ter lead connections.
SIGNIFICANT DC VOLTAGE exists after removal of D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
input power on inverters.
D Read instructions for test equipment.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any parts.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
STATIC (ESD) can damage PC boards. gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
D Put on grounded wrist strap BEFORE handling support unit.
boards or parts.
D If using lift forks to move unit, be sure forks are
D Use proper static-proof bags and boxes to long enough to extend beyond opposite side of
store, move, or ship PC boards. unit.
FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

D Do not place unit on, over, or near combustible D Keep away from moving parts such as fans.
surfaces. D Keep all doors, panels, covers, and guards
D Do not service unit near flammables. closed and securely in place.
XMT 304 TM-180 670 Page 1

MOVING PARTS can cause injury. H.F. RADIATION can cause interference.
D Keep away from moving parts. D High-frequency (H.F.) can interfere with radio
D Keep away from pinch points such as drive navigation, safety services, computers, and
rolls. 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 prompt-
ly correct any interference problem resulting from the installa-
MAGNETIC FIELDS can affect pacemak- tion.
ers. D If notified by the FCC about interference, stop using the
equipment at once.
D Pacemaker wearers keep away from servicing
D Have the installation regularly checked and maintained.
areas until consulting your doctor.
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.
OVERUSE can cause OVER-

READ INSTRUCTIONS.
HEATING.
D Use MILLER Testing Booklet (Part No. 150
D Allow cooling period; follow rated duty cycle. 853) when servicing this unit.
D Reduce current or reduce duty cycle before D Consult the Owner’s Manual for welding safety
starting to weld again. precautions.
D Do not block or filter airflow to unit. D Use only genuine MILLER replacement parts.
1-3. EMF Information

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the 4. Keep welding power source and cables as far away from opera-
committee’s judgment, has not demonstrated that exposure to power- tor as practical.
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as possi-
examined. Until the final conclusions of the research are reached, you ble.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.
TM-180 670 Page 2 XMT 304

SECTION 2 – DEFINITIONS
2-1. Manufacturer’s Warning Label Definitions
Warning! Watch Out! There are

possible hazards as shown by the
symbols.
1 Electric shock from welding
electrode or wiring can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Disconnect input plug or
power before working on
machine.
2 Breathing welding fumes can
1 1.1 1.2 1.3 be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
2 2.1 2.2 2.3 fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Do not weld near
flammables.
3 3.1 3.2 3.3 3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
4 4.1 injure skin.
+ + + 4.1 Wear hat and safety glasses.

Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
5 6 protection.
+ 5 Become trained and read the

instructions before working on
the machine or welding.
6 Do not remove or paint over
(cover) the label.
S-179 310
1/96
XMT 304 TM-180 670 Page 3

1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Electric shock from wiring can
kill.
3 Disconnect input plug or
1 2 3 4 5 6 power before working on
machine.
4 Hazardous voltage remains
on input capacitors after
power is turned off. Do not
V touch fully charged
V capacitors.
5 Always wait 60 seconds after
> 60 s V S-179 190-A power is turned off before
working on unit, OR
6 Check input capacitor voltage,
and be sure it is near 0 before
touching any parts.
4/96

shown by the symbols.
2 When power is applied failed
parts can explode or cause
other parts to explode.
1 2 3 4 5
3 Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
4 Always wear long sleeves and
button your collar when
servicing unit.
S-179 304-A 5 After taking proper
precautions as shown,
connect power to unit.
4/96

1 shown by the symbols.
2 Falling equipment can cause
injury and damage to unit.
3 Always lift and support unit
using both handles. Keep
angle of lifting device less
than 60 degrees.
∠ = <60 ° 4 Use a proper cart to move
unit.
∠ 5 Do not use one handle to lift
or support unit.
S-179 309-A
2 3 4 5
1/96
TM-180 670 Page 4 XMT 304

2-2. Manufacturer’s Rating Labels
XMT 304 TM-180 670 Page 5

2-3. Symbols And Definitions
A Amperage Panel
Alternating
Current (AC) V Voltage
Output Circuit Breaker Remote On
Gas Tungsten Arc

Off Negative Voltage Input
Welding
Direct Current Protective Earth

Positive Inductance
(DC) (Ground)
Constant Current Constant Voltage Foot Control Line Connection
Three Phase Static

Frequency Con-
Shielded Metal Arc Gas Metal Arc
Arc Force verter-
Welding (SMAW) Welding (GMAW)
Transformer-
Rectifier
U0 Rated No Load
Voltage (Average) U1 Primary Voltage
U2 Conventional
Load Voltage X Duty Cycle
Hz Hertz IP Degree Of
Protection I2 Rated Welding
Current % Percent
Lift-Arc Trigger
Pulsed Hold Operation Single Phase Three Phase
(GTAW)
I1max Rated Maximum

Supply Current I1eff Maximum Effective
Supply Current
Increase
Lift-Arc Operation
(GTAW)
TM-180 670 Page 6 XMT 304

SECTION 3 – INSTALLATION
3-1. Specifications
Amperes Input
Maximum at Rated Load
Rated Welding Voltage Amperage
Open-Circuit IP Rating Output 50/60 Hz
Output Range Range
Voltage DC
400 V KVA KW
300 A @
17.0 12.4 11.5
32 Volts DC, 10 – 35 5 – 400 90 23
(0.15*) (0.09*) (0.04*)
60% Duty Cycle
*While idling
3-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed (see
Section 8-3), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or duty cycle be-
fore welding.
Y Exceeding duty cycle can
damage unit and void war-
ranty.
60% Duty Cycle
6 Minutes Welding 4 Minutes Resting
Overheating
0 A
15
OR
Minutes Reduce Duty Cycle
Ref. SA-178 651
XMT 304 TM-180 670 Page 7

3-3. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amper-
age output capabilities of unit.
Curves of other settings fall be-
tween curves shown.
A. CC Mode
B. CV Mode
ARC CONTROL
va_curve1 4/95 – SA-178 652 / SA-178 653
TM-180 670 Page 8 XMT 304

3-4. Selecting A Location
24 in
(610 mm)
Dimensions And Weight
87 lb (39.5 kg)
17 in
(432 mm)
12-1/2 in
(318 mm)
Movement
1 Lifting Handles
1 Y Do not move or operate unit
where it could tip. Use handles to lift unit.
2 Hand Cart
Use cart or similar device to move
unit.
1 3 Plate Label
2
Use label to determine input power
needs.
4 Line Disconnect Device
Locate unit near correct input
power supply.
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Location
Section 20.
18 in
(460 mm)
18 in
(460 mm)
loc_2 3/96 - ST-801 192
XMT 304 TM-180 670 Page 9

3-5. Weld Output Terminals And Selecting Cable Sizes
Y ARC WELDING can cause Electromagnetic Interference.

To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
Total Cable (Copper) Length In Weld Circuit Not Exceeding*
100 ft (30 m)** 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft

Or Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 – 60% 60 – 100%
Weld Output Welding
Duty Duty 10 – 100% Duty Cycle
Terminals Amperes
Cycle Cycle
100 4 (20)** 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30)** 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
2-2/0 2-2/0
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)
2-2/0 2-3/0 2-3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
2-2/0 2-3/0 2-3/0 2-4/0

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)
+ 2-2/0 2-3/0 2-4/0 2-4/0

– 400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (2x120)
Output Receptacles
2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)
2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0

600 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120)
*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. S-0007-E
TM-180 670 Page 10 XMT 304

3-6. Remote 14 Receptacle Information
Socket* Socket Information
A 24 volts ac. Protected by circuit breaker CB2.

24 VOLTS AC
B Contact closure to A completes 24 volts ac con-
A J tactor control circuit.
K I
B
C L N H I 115 volts ac. Protected by circuit breaker CB1.
115 VOLTS AC
D M G
J Contact closure to I completes 115 volts ac con-
E F tactor control circuit.
C Output to remote control; 0 to +10 volts dc, +10

volts dc in MIG mode.
REMOTE
OUTPUT D Remote control circuit common.
CONTROL
E 0 to +10 volts dc input command signal from re-
mote control.
H Voltage feedback; +1 volt dc per 10 output recep-

tacle volts.
A/V
AMPERAGE F Current feedback; +1 volt dc per 100 amperes.
VOLTAGE
ST-801 192 M CC/CV select
G Circuit common for 24 and 115 volts ac circuits.

GND
K Chassis common.
*The remaining sockets are not used.
3-7. 110 Volt AC Duplex Receptacle

1 110 V 7 A AC Receptacle
Power is shared between duplex
receptacle and Remote 14 recep-
tacle (see Section 3-6).
2 Circuit Breaker CB1
1 CB1 protects 110 volt ac portion of
duplex receptacle and Remote 14
receptacle from overload.
CB2 protects 24 volt ac portion of
Remote 14 receptacle from
overload.
Press button to reset breaker.
2 3
Ref. ST-801 245-A
XMT 304 TM-180 670 Page 11

3-8. Electrical Service Guide
NOTE Actual input voltage should not exceed ± 10% of indicated required input voltage. If
actual input voltage is outside of this range, output may not be available.
Input Voltage 400 (Three Phase Only)
Input Amperes At Rated Output 17.0
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 30
Reference: 1996 National Electrical Code (NEC). S-0092J
“
3-9. Connecting Input Power
Y Disconnect and lockout/tag-
out input power before con-
necting input conductors
from unit.
Y Have only qualified persons
make this installtion.
Check input voltage available at
site.
1 Line Disconnect Device
2 Input And Grounding
1 Conductors
Select type and size of overcurrent
protection using Section 3-8.
Y Always connect green/yel-
L1 low wire to supply ground-
L2 ing terminal, never to a line
Y Always connect grounding terminal.
conductor first. L3
= GND/PE 2
Green/Yellow
Install conductors into a deenergized
line dissconnect device.
Tools Needed:
Input_9_99 / Ref. ST-144 221 / ST-801 192
TM-180 670 Page 12 XMT 304

SECTION 4 – OPERATION
4-1. Front Panel Controls
1 2 3 4
7 5 6
ST-179 275
1 Power On/Off Switch best results, place Inductance/Dig control in When set lower, short-circuit amperage at
the maximum position. low arc voltage is the same as normal welding
. The fan motor is thermostatically 6 Voltage/Amperage Control Switch amperage.
controlled and only runs when cooling is For front panel control, place switch in Panel
needed. When set higher, short-circuit amperage is in-
position. creased at low arc voltage to assist with arc
2 Voltmeter (see Section 4-2) For remote control, make connections to Re- starts as well as reduce sticking while weld-
3 Ammeter (see Section 4-2) mote 14 receptacle, and place switch in ing (see volt-ampere curves in Section 3-3).
Remote position. In most modes, remote
4 Voltage/Amperage Adjustment Control control is a percent of the Voltage/Amperage Select setting best suited for application.
5 Mode Switch Adjustment control setting (the value se-
lected on Voltage/Amperage Adjustment Control adjusts inductance when a MIG
The Mode switch setting determines both the control is maximum available on remote). In (GMAW) position is selected on the mode
process and output On/Off control (see Sec- the MIG mode, remote control provides full switch. Inductance determines the “wetness”
tion 4-3. Source of control (panel or remote) range of unit output regardless of V/A Adjust of the weld puddle. When set higher, “wet-
for the amount of output is selected on the control setting. ness” (puddle fluidity) increases.
Voltage/Amperage Control switch.
7 Inductance/Dig Control When pulsed MIG, or one of the TIG (GTAW)
For Air Carbon Arc (CAC-A) cutting and Control adjusts Dig when a Stick (SMAW) processes is selected, this control is not func-
gouging, place switch in Stick position. For welding position is selected on mode switch. tional.
XMT 304 TM-180 670 Page 13

4-2. Meter Functions
NOTE The meters display the actual weld output values for approximately three seconds
after the arc is broken.
Mode Meter Reading At Idle Meter Reading While Welding
V A V A
Lift-Arc Trigger
Hold TIG (GTAW) 85 10.3 85
Blank Preset Amps Actual Volts Actual Amps
V A V A
TIG (GTAW) 85 10.3 85

V A V A
MIG (GMAW) 24.5 24.5 250

Preset Volts Blank Actual Volts Actual Amps
V A V A
Pulsed MIG
(GMAW-P)
PPP PPP 24.5 250
Pulse Display Pulse Display Actual Volts Actual Amps
V A V A
Remote
Control SMAW
85 24.5 85
V A V A
Panel Control
SMAW 85.0 85 24.5 85
Actual Volts (OCV) Preset Amps Actual Volts Actual Amps
TM-180 670 Page 14 XMT 304

4-3. Mode Switch Settings
NOTE 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
Select: or Amp
Lift-Arc Trigger
Hold TIG (GTAW)
Requires: Control
TIG (GTAW) With Select: or Amp

HF Unit,
Pulsing Device,
Or Remote Control Requires: Control
Select: or Volt
MIG (GMAW)
Requires: Feeder
Pulsed MIG
(GMAW-P) Select: Volt
(Requires an
external
pulsing device.) Requires: Feeder or Control
Select: or Amp
Remote
Control SMAW
Requires: Control
Select: or Amp
Panel Control
SMAW
Weld
XMT 304 TM-180 670 Page 15

4-4. Lift-Arc Trigger Hold TIG
1 TIG Electrode
2 Workpiece
. Procedure requires:
control
Start sequence:
1 2
• Touch tungsten electrode to
workpiece at weld start point.
• Momentarily depress output
switch.
• Slowly lift electrode. An arc will
1–2 form when electrode is lifted.
“Touch” Seconds
• To stop welding, momentarily
depress output switch and out-
put will shut off.
Note: If output switch is momen-
tarily depressed and tungsten is
not touching workpiece:
Do not touch tungsten to work.
Output will shut off in 3 seconds.
Start sequence over.
Do NOT Strike Like A Match!
Ref. S-156 279
TM-180 670 Page 16 XMT 304

Notes
XMT 304 TM-180 670 Page 17

SECTION 5 – THEORY OF OPERATION
1 Power On/Off Switch S1
Provides on/off control of welding
power source. 1 18 19 20
2 Filter Board PC6 Three-Phase Power On/ Input
Line Input Inductor L1, Inductors
Off Switch Capacitors
Filters line input power. Power S1 C3, C4 Choke T3 L3, L4
3 Input Rectifier SR1
Changes the ac line input power to
full-wave rectified dc. 2 3 21
4 Control Transformer T2 SCR/
Filter Board Integrated Interconnecting
Supplies power to control board PC6 Rectifier SR1 Board PC2
PC1, interconnecting board PC2,
and Remote 14 receptacle RC1. 190
5 Circuit Breaker CB1 VAC
10 23 23
Provides overload protection for
115 volts ac portion of Remote 14 Input IGBT Power IGBT Power
Contactor Module PM1 Module PM2
receptacle RC1 and optional 115 W1
volt ac receptacle.
Provides overload protection for 24 4 22 22
volts ac portion of Remote 14
receptacle RC1. Control IGBT Board IGBT Board
Transformer T2 PC4 PC5
7 115 Volt AC Receptacle
Connects auxiliary equipment to
welding power source (optional for 18
CC models). VAC
Center- Gating Gating
8 Remote 14 Receptacle RC1 115 24 190 Signals Signals
VAC VAC Tapped VAC
Connects remote amperage or
voltage and contactor controls.
7
9 Control Board PC1 9
Controls weld output by changing 115 Volts AC
gate pulses (frequency of pulses) to Receptacle
IGBT power modules PM1 and
PM2 after comparing current or Control Board PC1
voltage feedback to reference level
set by R2 on PC3. 8 5
10 400 V Input Contactor W1 Circuit
Breaker
Connects the 190 volts ac secon- CB1
dary voltage from T2 to intercon- 11
necting board PC2 to balance volt-
6
age on input capacitors C3 and C4. Fan Motor
Effective w/KK104771, this circuit Circuit FM
has been removed. Breaker
CB2
11 Fan Motor FM Remote 14
Receptacle Ribbon
Provides cooling of internal compo- RC1 Cable
nents.
12 Display Board PC3 12
Consists of voltmeter V, ammeter Display Board PC3
A, Inductance/Dig control R44,
Voltage/Amperage Adjustment 13 13
control R2, Mode switch S3, and
Voltage/Amperage Control switch Voltmeter Ammeter
S2. V A
13 Voltmeter V, Ammeter A
14 15
See Section 4-2. Voltage/
Inductance/ Amperage
14 Inductance/Dig Control R44 Dig Control
(CC/CV Models) Or Dig R44 Adjustment
Control R44 (CC Models) Control R2
In CV mode, R44 functions as an in- 16 17
ductance control modifying the re- Voltage/
sponse of the arc. In CC mode, R44 Mode Switch Amperage
functions as a dig control. S3 Control
Switch S2
TM-180 670 Page 18 XMT 304

15 Voltage/Amperage Adjustment
Control R2 (CC/CV Models) Or
Amperage Adjustment Control
R2 (CC Models)
Selects weld output voltage or am-
perage level. Setting defines maxi-
mum output when remote voltage
24 and/or amperage control is used and
Current Mode switch S3 is in a CC position.
25 26 27
Transformer 16 Mode Switch S3
CT1 Series Main Output
Resonant Transformer Diodes Selects type of weld output, meter
Capacitor C1 T1 D1, D2 function, and remote contactor or
front panel for welding process.
17 Voltage/Amperage Control
Switch S2 (CC/CV Models) Or
Amperage Control Switch S2
(CC Models)
T1 Primary 28 29
Current Selects front panel or remote voltage
Hall or amperage control.
Feedback Stabilizer Device
Z1 HD1 18 Input Capacitors C3, C4
Filter the dc output voltage of SR1.
19 Inductor L1, Choke T3
Limit peak current in SR1, C3, and
30 30 C4, and filter line input power.
Negative (–) Positive (+) 20 Inductors L3, L4
Weld Output Weld Output
Receptacle Receptacle Limit voltage and current in IGBT’s
during turn-on and turn-off.
21 Interconnecting Board PC2
Provides electrical connections for
Work SR1, T1, C1, C3, C4, L1, L3, L4, T3,
Electrode and IGBT’s. Precharge and bleeder
resistors are mounted on PC2.
22 IGBT Boards PC4, PC5
Current Feedback
Provide interconnection of gate
pulses from PC1 to PM1 and PM2.
23 IGBT Power Modules PM1,
PM2
Use very fast on/off switching action
to effectively turn the dc into ac.
24 Current Transformer CT1
Provides current feedback to PC1
from the primary of T1 for control cir-
cuit timing and to limit primary cur-
rent.
25 Series Resonant Capacitor C1
Reduces losses in IGBT power mod-
ules PM1 and PM2.
26 Main Transformer T1
Voltage Feedback Energized by on/off switching action
of PM1 and PM2, and supplies pow-
Voltage Feedback
er to weld output circuit.
27 Output Diodes D1, D2
Rectify output of T1.
28 Stabilizer Z1
Smooths out welding current.
29 Hall Device HD1
AC Or DC Control Circuits Provides weld or secondary current
feedback signal to PC1.
3φ Power 30 Positive (+) And Negative (–)
Weld Output Receptacles
Provide weld output and allow
Weld Current Circuit changing of output polarity.
XMT 304 TM-180 670 Page 19

SECTION 6 – EXPLANATION OF ELECTRICAL PARTS
elect_parts 1/01
6-1. Safety Precautions – Read Before Using This Guide
Y WARNING: ELECTRIC SHOCK can kill.

D Disconnect input power or stop engine before servicing.
D Do not touch live electrical parts.
D Do not operate machines with covers removed.
D Have only qualified persons install, use, or service equipment.
6-2. Explanation Of Electrical Parts

PART NAME FUNCTION PICTURE CIRCUIT SYMBOL
CAPACITOR A device that stores electrical energy. Large

POLARIZED NON-POL.
capacitors or a “bank” of capacitors can be
used to “smooth out” the DC welding arc in a
MIG welding power source. Smaller “disk” C1 C1
capacitors can be used for HF protection.
CIRCUIT BREAKER A protection device that breaks a circuit when

current levels exceed its rating. Unlike a fuse CB1
that needs to be replaced when blown, a
circuit breaker can be reset.
DIODE A device that allows current to flow in one

direction only. Most common use is to D1
change AC to DC.
FUSE A protection device, usually an enclosed

piece of wire that melts and breaks the circuit F1
when the current exceeds the fuse rating.
HALL DEVICE Produces a small DC voltage proportional to

the current it is sensing (usually welding HD1
current). This feedback signal can be used to
regulate the welding output (line voltage
compensation). It may even be used to drive
an ammeter.
RESISTOR A device which resists the flow of electric FIXED R1

current. Uses include limiting the current for a
motor brake circuit in a wire feeder and for
discharging a capacitor.
FIXED TAPPED R1
POTENTIOMETER Both devices have a moveable brush that

OR makes contact along a resistor, allowing you
RHEOSTAT to easily change the resistance measured at
the brush (sometimes referred to as a wiper).
Their primary purpose is to give the operator VARIABLE R1
a way to adjust welding parameters such as
wire speed, preflow time, voltage,
inductance, etc.
TM-180 670 Page 20 XMT 304

FAN MOTOR This device provides cooling of the internal

parts of a welding power source.
FM
VARISTOR A protection device whose resistance is

dependent on the voltage applied to it. In
normal operation it has a high resistance; VR1
however, a surge of voltage (voltage spike)
will cause its resistance to go way down and
absorb the spike. These devices are most
often found in rectifying circuits, where they
are used to protect the diodes.
GAS OR WATER These are electromechanical devices used to

SOLENOID start or stop the flow of shielding gas or
(VALVE) water. GS1
OR
WS1
RELAY––COIL AND This is an electromechanical device whose COIL

CONTACTS, contacts change state (the normally open
NORMALLY OPEN points close and the normally closed points
AND NORMALLY open) when proper voltage is applied to the
CLOSED coil. These contact points in turn may control CR1 CR1
a fan motor, gas solenoid, contactor, etc.
Circuit diagrams (schematics) always show NRM OPEN NRM CLOSED
the contact points in the power off state. POINTS POINTS
THERMOSTAT, This is a switch that closes its normally open

NORMALLY OPEN contacts (or opens its normally closed
AND NORMALLY contacts) when a preset temperature is TP1 TP1
CLOSED reached. When the temperature goes back
down, it will reset itself. Uses of these
devices include turning on a fan motor when NRM OPEN NRM CLOSED
needed and shutting off the output of a
welding power source if it is overheating.
CONTACTOR A heavy duty relay. Usually used to make

and break the welding arc or primary power. COIL
W
W
NRM OPEN
POINTS
PILOT LIGHT A light located on the front panel which

1
indicates if the machine is on or off.
PL
STABILIZER/ When placed in a DC circuit, the inductor or

REACTOR stabilizer as it is usually called, will oppose
any change in existing current. It is therefore Z1
widely used to “stabilize” the welding arc.
When the inductor is placed in an AC circuit it
is referred to as a reactor where it now acts L1
to restrict the flow of current. A “tapped
reactor” is used to create current ranges for
welding.
XMT 304 TM-180 670 Page 21

MOTOR A device that is typically used to feed wire in

a MIG welding system.
B1
SHUNT A precision low-value resistor typically used

to supply a small voltage to drive an
SHUNT
ammeter.
MOSFET A device that is used as an “electronic D

switch”. When a signal is applied to the gate
(G), current is allowed to flow from the source
(S) to the drain (D). This device can be used
G
to control a relay, the speed of a motor, or
even the output of a welding machine. AS
S
IGBT A device that is used as an “electronic

switch”. When a signal is applied to the gate C1
(G), current is allowed to flow from the emitter
(E) to the collector (C). This device is typically G1 (B1)
used in “Invertor” designed welding machines
to control the welding output. E1
BRUSHES/SLIP Components that allow electrical connections

RINGS between stationary and rotating contacts.
SLIP
RINGS
BRUSHES
TERMINAL STRIP An insulated connection point for wires. They

are used for the ease of making multiple
connections and can be a convenient point 42 42 104 105 74
1T
for making electrical checks when A B C D E
troubleshooting. (Notice the “jumper link”
connecting terminals A and B together.)
SWITCH A mechanical device that completes or SPST SPDT

breaks the path of the current or sends it over
a different path.
DPST DPDT
TM-180 670 Page 22 XMT 304

SCR A Silicon Controlled Rectifier (SCR) is an

electrical device with three connections,
anode, cathode, and gate. It will allow current K
G
to flow in only one direction and will only do
so after receiving a signal on the gate lead.
SCR’s are used to change AC to DC and to A
control the output to a load such as a welding
arc.
THERMISTOR A thermally sensitive resistor. The resistance

RT1
of a thermistor changes with a change in
temperature. Primarily used for “Fan on OR
Demand” and “Thermal Shutdown” circuits. TH1
TRANSFORMER A device that changes AC voltage from one

magnitude to another. Typically used to
reduce high primary voltages to lower
welding voltages.
T1
INTEGRATED An arrangement of four diodes used to AC +

BRIDGE change AC to DC. AC
RECTIFIER +
–
AC _ AC
SPARK GAP The arrangement of two electrodes between

which a discharge of electricity will occur.
Typically used to produce “ high frequency”
which can be used for arc starting when TIG
welding. G
CURRENT A transformer that produces an AC voltage CT1

TRANSFORMER used for measuring purposes. The primary
winding is in series with the circuit carrying
the current to be measured. Its main use in OR
engine-driven equipment is to activate the
“Automatic Idle” circuit by sensing welding
current or auxiliary power current. CT1
XMT 304 TM-180 670 Page 23

SECTION 7 – PRE-POWER CHECKLIST
7-1. Checking Unit Before Applying Power

. See Section 8-4 or 8-5 for test points and values and
Section 11 for parts location.
Y Discharge input capacitors according to Section 9-3 and be sure voltage is near zero before touching any parts.
Y Before troubleshooting or applying power to unit, complete following checks to avoid causing further damage.
Y Although control board PC1 and hall device HD1 are briefly checked in this procedure, more complete tests may be needed later for
these parts. This check is simply to get a basic okay to power up unit.
NOTE The pre-power checklist should be followed if any of the following conditions exist:
the unit is completely inoperative;
the symptoms are unknown;
visual damage is found on any of the following components: capacitors C3 and C4,
control board PC1, IGBT power modules PM1 and PM2, interconnecting board
PC2, or input rectifier SR1;
there is no output or limited output.
7-2. Output Diodes D1, D2

Y Read and follow safety
information in Section 7-1
before proceeding.
1 First, check resistance across
weld output receptacles
(ohms position). Resistance
should be greater than 100
ohms.
2 If resistance is less than 100
ohms, isolate diodes D1 and
D2 and retest individually
(diode test).
–
Weld Output
Receptacles
+
Test Equipment Needed:
Diodes D1, D2
Ref. SD-183 484 / ST-801 705
TM-180 670 Page 24 XMT 304

7-3. Input Rectifier SR1
before proceeding.
. Resistance values are based

on in-circuit measurements.
1 Visually inspect SR1 for
damage.
2 Check 6 diodes (diode test).
Check from each ac terminal
to the positive (+) terminal and
from each ac terminal to the
negative (–) terminal.
3 Check precharge SCR (ohms
position). Connect negative
lead to SCR (–) terminal and
positive lead to positive (+)
Power Switch S1 terminal. Resistance should
be 200 ohms ±10%. If meter
reads infinite resistance (OL),
check resistor R7 on
interconnecting board PC2.
Connect a jumper between
positive (+) and gate
terminals. Resistance should
be approximately 35 ohms.
Negative (–)
4 If results are in doubt, use an
IGBT tester (MILLER Part No.
–
043 553) to test the SCR
AC (L1) portion of SR1 as follows:
SCR (–)
A. Disconnect plug PLG13
T from receptacle RC1 on in-
Gate + AC (L2) terconnecting board PC2.
B. Connect red clip to positive
G S (+) terminal.
Positive (+) AC (L3) C. Connect black clip to SCR
(–) terminal.
R2 R D. Connect yellow clip to gate
terminal.
5 If SR1 is defective, check the
Input Rectifier SR1 three poles of power switch
S1 (switch off = OL, switch on
= 0 ohms).
ST-801 550 / Ref. SD-183 484
7-4. Tank Capacitor C1 and Input Capacitors C3, C4

before proceeding.
. This is not a conclusive test.

For best results use a capacitor
tester to check capacitance.
. If either C3 or C4 is shorted, re-

move interconnecting board
PC2 and check IGBT’s PM1
and PM2.
Input Capacitors C3, C4 1 Check C1, C3, and C4 for a
short (ohms position).
Tank Capacitor C1
ST-801 550
XMT 304 TM-180 670 Page 25

7-5. IGBT Modules PM1, PM2
before proceeding.
. It is not necessary to remove

interconnecting board PC2 to
test the IGBT’s unless input ca-
pacitor C3 or C4 is shorted.
1 Visually inspect PM1 and
PM2 for damage.
2 Disconnect gate lead plug
PLG5 from receptacle RC5 on
control board PC1.
3 Check C1 to E1 and C2 to E2
on PM1 and PM2 for
resistance greater than 100
ohms (ohms position). Zero
ohms indicates a short.
4 Check E1 to PLG5-10 and E2
to PLG5-7 for 100 k ohms
±10% (ohms position) on
PM1. Then check E1 to
PLG5-6 and E2 to PLG5-9 for
100 k ohms ±10% (ohms
position) on PM2.
IGBT Board 5 If results are in doubt, use an
PC4 Or PC5 IGBT tester (MILLER Part No.
043 553) as follows:
A. Check two IGBT’s per
G2 (B2) G1 (B1) module.
B. Connect red clip to C.
C. Connect black clip to E.
Terminal D. Connect yellow clip to G
C1 (white leads at plug PLG5).
6 If IGBT’s are defective, check
Terminal D1, D2, D3, and D4 on PC2
E2 (see Section 7-6).
Terminal
C2/E1
IGBT Module PM1 Or PM2

ST-801 550 / Ref. SD-183 484
TM-180 670 Page 26 XMT 304

7-6. Diodes D1, D2, D3, D4
before proceeding.
1 Check D1 and D2 on PC2 for
2000 ohms ±10%.
2 Prior to Serial No. KK276107,
check D3 and D4 on PC2
(diode test). Effective with
Serial No. KK276107, these
diodes are no longer present.
Previous Previous
Location Of Location Of
Diode D3 Diode D4
Diode Diode
D1 D2
Interconnecting Board PC2
ST-801 550 / 195 587
XMT 304 TM-180 670 Page 27

SECTION 8 – TROUBLESHOOTING
8-1. Troubleshooting Table
. See Section 8-4 or 8-5 for test points and values

and Section 11 for parts location.
. Use MILLER Testing Booklet (Part No. 150 853)

when servicing this unit.
Trouble Remedy
No weld output; unit completely Place line disconnect switch in On position (see Section 3-9).
inoperative. Follow pre-power checklist
(see Section 7).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-9).
Check for proper input power connections (see Section 3-9).
Check continuity of Power switch S1, and replace if necessary.
Check filter board PC6 for proper connections. Check input and output voltages. Replace PC6 if nec-
essary.
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.
No weld output; meter display On. If using remote control, be sure Voltage/Amperage Control switch S2 (CC/CV models) or Amperage
Follow pre-power checklist (see Control switch S2 (CC models) is in Remote 14 position.
Section 7).
Prior to Serial No. KG150087, input voltage outside acceptable range of variation (see Section 8-2).
Effective with Serial No. KG150087, see Section 8-3 for HELP screens.
Unit overheated and HELP 3 or HELP 5 screen is displayed. Allow unit to cool with fan On (see Sec-
tion 8-2 or 3-2).
Check, repair, or replace remote control.
Check resistance and connections of hall device HD1; HD1 is 1800 ohms ±10% between pins 1 and
3 of plug PLG9. Check input and output voltages. Replace HD1 if necessary.
Check output diodes D1 thru D2, and replace if necessary.
Check input integrated rectifier SR1, and replace if necessary.
Check IGBT modules PM1 and PM2, and replace if necessary.
Check control board PC1 and connections, and replace if necessary (see Section 8-7).
Low weld output with no control. Check position of Voltage/Amperage Control switch S2 (see Section 4-1).
Check display board PC3 and connections, and replace if necessary (see Section 8-9).
Maximum weld output with no control. Check resistance and connections of hall device HD1; HD1 is 1800 ohms ±10% between pins 1 and
Check volt sense lead connections from weld output studs to PC1.
Limited output and low open-circuit Check incoming power for correct voltage. Replace line fuse if open (see Section 3-9).
voltage.
Check for proper input and output connections.
If using remote amperage/voltage control, check position of Amperage/Voltage control R2.
Check connection at stabilizer and T1 transformer.
TM-180 670 Page 28 XMT 304

Trouble Remedy
Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-5).
Clean and tighten all weld connections.
Check for proper input and output connections.
Replace electrode.
Check resistance and connections of remote amperage control potentiometer, and replace if
necessary.
No 24 volts ac output at Remote 14 Reset circuit breaker CB2 if necessary (see Section 3-7).
receptacle RC1.
Check Remote 14 receptacle RC1 wiring and connections.
No 115 volts ac output at Remote 14 Reset circuit breaker CB1 if necessary (see Section 3-7).
receptacle RC1 or optional duplex
receptacle.
Check receptacle(s) wiring and connections.
Fan motor does not run after approxi- Check and clear blocked fan blade.
mately four minutes of operation at
rated load.
Check thermistors RT1 and RT2 on display board PC3 (see Section 8-9).
Check coil voltage and connections of fan motor FM. Check continuity of coil. Replace FM if
necessary.
Wandering arc; poor control of arc Use proper size tungsten.

direction.
Use properly prepared tungsten.
Reduce gas flow rate.
Tungsten electrode oxidizing and not Shield weld zone from drafts.
remaining bright after conclusion of
weld.
Increase postflow time.
Check and tighten all gas fittings.
Water in torch. Refer to torch manual.
XMT 304 TM-180 670 Page 29

8-2. Voltmeter/Ammeter Help Displays Prior To Serial No. KG150087
1 Help 1 Display
Indicates a malfunction in the pri-
mary power circuit of the unit. If this
display is shown, check tank ca-
pacitor C1 (see Section 7-4) and
V A control board PC1 (see Section
1 8-7).
2 Help 2 Display
HE.L P–1 Indicates a malfunction in the ther-
mal protection circuitry of the unit. If
this display is shown, check therm-
istors RT1 and RT2, and display
V A board PC3 (see Section 8-9).
2 3 Help 3 Display
Indicates the unit has overheated
HE.L P–2 and has automatically shut down to
allow the fan to cool it (see Section
3-2). Operation will continue when
the unit has cooled down.
4 Help 4 Display
V A
3 Indicates that the input voltage is
too low and the unit has automati-
HE.L P–3 cally shut down. Operation will con-

tinue when the voltage is within the
operating range (±15%). Have an
electrician check the input voltage if
this display is shown.
V A 5 Help 5 Display
4 Indicates that the input voltage is
too high and the unit has automati-
HE.L P–4 cally shut down. Operation will con-
tinue when the voltage is within the
operating range (±15%). Have an
electrician check the input voltage if
this display is shown.
V A 6 Help 6 Display
5
Indicates a malfunction in the sec-
HE.L P–5 ondary power circuit of the unit. If

this display is shown, check control
board PC1 (see Section 8-7).
V A
6
HE.L P–6
TM-180 670 Page 30 XMT 304

8-3. Voltmeter/Ammeter Help Displays Effective With KG150087
V A V A
1 6
HE.L P–0 HE.L P–5

V A V A
2 7

V A V A
3 8

V A V A
4 9

V A V A
5 10
. All directions are in reference to the front heated. The unit has shut down to allow the
fan to cool it (see Section 3-2). Operation will
shown, have an electrician check the input
voltage.
of the unit. All circuitry referred to is lo-
continue when the unit has cooled. 8 Help 7 Display
cated inside the unit.
1 Help 0 Display 5 Help 4 Display Indicates that the input voltage is too high and
the unit has automatically shut down. Opera-
Indicates a shorted thermistor RT2 on the left Indicates a malfunction in the thermal protection will continue when the voltage is within
side of the unit. If this display is shown, check tion circuitry located on the right side of the the acceptable upper range limit (15% above
thermistor RT2. unit. If this display is shown, check thermistor the applicable input voltage). If this display is
2 Help 1 Display RT1 and display board PC3 (see Section shown, have an electrician check the input
8-9). voltage. Effective with KK104771, Help 7 can
Indicates a malfunction in the primary power
circuit. If this display is shown, check tank ca- 6 Help 5 Display also indicate a bus voltage imbalance.
pacitor C1 (see Section 7-4), control board 9 Help 8 Display
Indicates the right side of the unit has over-
PC1 (see Section 8-7), and display board heated. The unit has shut down to allow the Indicates a malfunction in the secondary
PC3 (see Section 8-9). fan to cool it (see Section 3-2). Operation will power circuit of the unit. If this display is
3 Help 2 Display continue when the unit has cooled. shown, check control board PC1 (see Sec-
tion 8-7). When this occurs, have an electri-
Indicates a malfunction in the thermal protec- 7 Help 6 Display cian check the primary and secondary con-
tion circuitry located on the left side of the unit. nections.
If this display is shown, check thermistor RT2 Indicates that the input voltage is too low and
the unit has automatically shut down. Opera- 10 Help 9 Display
and display board PC3 (see Section 8-9).
tion will continue when the voltage is within Indicates a shorted thermistor RT1 on the
4 Help 3 Display the acceptable lower range limit (15% below right side of the unit. If this display is shown,
Indicates the left side of the unit has over- the applicable input voltage). If this display is check thermistor RT1.
XMT 304 TM-180 670 Page 31

8-4. Troubleshooting Circuit Diagram For Welding Power Source Prior To KK104771
Y Discharge input capacitors according to Section 9-3, and be sure Test Equipment Needed:
voltage is near zero before touching any parts.
. No calibration available for voltmeter V or ammeter A.
R1
See Section 5 for V8

PC6 information
V1 V2
V3 V7
V5 V6
V4
See Section 5 for
PC4 information
See Section 8-9 for See Section 8-7

RT1, RT2 information for PC1 data
See Section
3-6 for RC1
information See Section 8-9
for PC3 data
TM-180 670 Page 32 XMT 304

Resistance Values
a) Tolerance – ±10% unless specified
b) Turn Off unit and disconnect input
power before checking resistance Voltage Readings
R1 thru R9 Less than 1 ohm a) Tolerance – ±10% unless specified
c) Reference – single arrow: reference
R2 to circuit common (lead 42); double
arrow: reference to points indicated
See Section 8-11 for
PC2 information c) Wiring Diagram – see Section 10
V1, V2 200 volts ac

V3 24 volts ac
R3 V9 V4 115 volt ac
V10 V5, V6 18 volts ac
V7 190 volts ac
V8 565 volts dc
V9, V10 282 volts dc
V11 28 volts dc when fan FM is running
R6 V12 24 volts dc
R4 R5
V13 1.5 volts dc per 100 amperes of
weld output
V14 –15 volts dc
V15 87 volts dc open-circuit voltage
See Section 5 for

PC5 information
V11
R8
R7
V14
V13
V15,
A, B
V12
See Section 8-6
for waveforms A, B
SC-181 838-C
XMT 304 TM-180 670 Page 33

8-5. Troubleshooting Circuit Diagram For Welding Power Source Eff. With KK104771
Y Discharge input capacitors according to Section 9-3, and be sure Test Equipment Needed:
voltage is near zero before touching any parts.
. No calibration available for voltmeter V or ammeter A.
R1
V7
See Section 5 for
PC6 information
V1 V2
V3 V5 V6
V4
See Section 5 for

PC4 information
See Section 8-7

for PC1 data
See Section 8-9 for
RT1, RT2 information
See Section
3-6 for RC1 See Section 8-9
information for PC3 data
TM-180 670 Page 34 XMT 304

Resistance Values
a) Tolerance – ±10% unless specified
b) Turn Off unit and disconnect input
power before checking resistance Voltage Readings
R1 thru R9 Less than 1 ohm a) Tolerance – ±10% unless specified
c) Reference – single arrow: reference
R2 to circuit common (lead 42); double
See Section 8-11 for arrow: reference to points indicated
PC2 information c) Wiring Diagram – see Section 10
V1, V2 200 volts ac

V3 24 volts ac
R3 V8 V4 115 volt ac
V9 V5, V6 18 volts ac
V7 565 volts dc
V8, V9 282 volts dc
V10 28 volts dc when fan FM is running
V11 Ground
V12 1 volt dc per 100 amperes of weld
R6 output
R4 R5
V13 –15 volts dc
V14 +15 volts dc
V15 87 volts dc open-circuit voltage
See Section 5 for

PC5 information
V10
R8
R7
V14
V13
V15,
A, B
V12
See Section 8-6
V11
for waveforms A, B
SC-197 552
XMT 304 TM-180 670 Page 35

8-6. Waveforms For Sections 8-4 And 8-5
10 µs 20 V 10 µs 20 V
gnd gnd
A. CC Or CV Mode, DC Open-Circuit Voltage B. CC Or CV Mode, 25 Volts DC, 200 Amperes

(Resistive Load)
TM-180 670 Page 36 XMT 304

8-7. Control Board PC1 Testing Information (All Models – Use With Section 8-8)
Y Discharge input capacitors
according to Section 9-3,
6 1 and be sure voltage is near
zero before touching any
parts.
Be sure plugs are secure before
4 testing. See Section 8-8 for specific
values during testing.
5 1 Control Board PC1
2 Receptacle RC1
3 Receptacle RC2
4 Receptacle RC3
5 Receptacle RC5
6 Receptacle RC6
7 Receptacle RC7
8 Receptacle RC8
3 9 Receptacle RC9
8 2
ST-801 550 / SC-182 085
XMT 304 TM-180 670 Page 37

8-8. Control Board PC1 Test Point Values (All Models)
a) Tolerance – ±10% unless

specified
PC1 Voltage Readings
b) Reference – to circuit common
(lead 42) unless noted
Receptacle Pin Value
RC1 1 +24 volts dc output
2 Not used
3 +24 volts dc output
4 +1 volt dc output per 10 volts dc of weld output
5 –24 volts dc output
6 +15 volts dc output when HELP 1 screen is displayed, 0 volts dc with normal conditions
7 –24 volts dc output
8 0 to +10 volts dc input from min to max of Inductance/Dig control R44 (CC/CV models) or Dig control
R44 (CC models)
9 Circuit common
10 Circuit common
11 –24 volts dc input with fan motor FM off, –10 volts dc with fan motor FM on
12 Prior to Serial No. KG150087, circuit common; effective with Serial No. KG150087, 0 volts dc output
during normal operation, +15 volts dc output when HELP 8 screen is displayed
13 +15 volts dc input with Mode switch S3 in lift arc position
14 Prior to Serial No. KG150087, circuit common; effective with Serial No. KG150087, +15 volts dc out-
put during normal operation, 0 volts dc output when HELP 6 screen is displayed
15 +15 volts dc input with Mode switch S3 in Dig (SMAW) position, 0 volts dc input with S3 in GMAW or
GTAW position
16 Prior to Serial No. KG150087, circuit common; effective with Serial No. KG150087, +15 volts dc out-
put during normal operation, 0 volts dc output when HELP 7 screen is displayed
17 +15 volts dc input with weld output on, 0 volts dc input with weld output off
18 +15 volts dc input with Mode switch S3 in droop (stick) position, 0 volts dc input with S3 in GMAW or
GTAW position
19 For CC/CV models only, +1.0 to +3.5 volts dc input, CV preset
20 +1 volt dc output per 100 amperes of weld output
21 +15 volts dc input with Mode switch S3 in CV position, 0 volts dc input with S3 in CC position (always
0 volts dc for CC models)
22 0 to +10 volts dc input from min to max of Voltage/Amperage Adjustment control R2 (CC/CV models)
or Amperage Adjustment control R2 (CC models); +13 volts dc in Pulse mode and weld output off
23 Prior to Serial No. KG150087, negative (–) voltage feedback input with respect to pin RC1-24;
effective with Serial No. KG150087, not used
24 Prior to Serial No. KG150087, positive (+) voltage feedback input with respect to pin RC1-23;
RC2 1 +1.5 volts dc input per 100 amperes of weld output (Prior to KK104771)
Not used (Effective w/KK104771)
2 18 volts ac input with respect to pin RC2-5 (Prior to KK104771)

3 18 volts ac input with respect to pin RC2-5 (Prior to KK104771)

4 +24 volts dc output (Prior to KK104771)

5 Circuit common (Prior to KK104771)

18 volts ac input with respect to pin RC2-11 (Effective w/KK104771)
TM-180 670 Page 38 XMT 304

RC2 6 Circuit common (Prior to KK104771)

18 volts ac input with respect to pin RC2-11 (Effective w/KK104771)
7 +15 volts dc output (Prior to KK104771)

8 –15 volts dc output (Prior to KK104771)

9 +1 volts dc input per 100 amperes of weld output (Effective w/KK104771)
10 Circuit common (Effective w/KK104771)
13 +15 volts dc output (Effective w/KK104771)
14 –15 volts dc output (Effective w/KK104771)
RC3 1 Do not measure – high voltage present
2 Do not measure – high voltage present
5 Not used
6 Negative (–) of C4 282 volts dc with respect to pin RC3-8 (Effective w/KK104771)
7 Not used
8 Positive (+) of C4 282 volts dc with respect to pin RC3-6 (Effective w/KK104771)
9 Not used
10 Positive (+) of C3 282 volts dc with respect to pin RC3-12 (Effective w/KK104771)
11 Not used
12 Negative (–) of C3 282 volts dc with respect to pin RC3-10 (Effective w/KK104771)
RC4 –– Not used
RC5
Make no connections – damage to test equipment or components can occur.
RC6 1 Current transformer CT1 feedback input with respect to pin RC6-2
2 Current transformer CT1 feedback input with respect to pin RC6-1
RC7 1 Reference for pins RC7-4 and RC7-5
2 190 volts ac input with respect to black/white lead of control transformer T2 (Prior to KK104771)
3 190 volts ac input with respect to pin RC7-2 after precharge (Prior to KK104771)
4 0 volts dc during precharge, +0.27 volts dc after precharge with respect to pin RC7-1
5 0 volts dc after precharge, +0.6 volts dc at power-up with respect to pin RC7-1
6 Not used
RC8 1 +28 volts dc output with respect to pin RC8-2
2 –28 volts dc output with respect to pin RC8-1
RC9 1 Prior to Serial No. KG150087, not used; effective with Serial No. KG150087, negative (–) voltage
feedback input with respect to pin RC9-3
2 Not used
3 Prior to Serial No. KG150087, not used; effective with Serial No. KG150087, positive (+) voltage feed-
back input with respect to pin RC9-1
XMT 304 TM-180 670 Page 39

8-9. Display Board PC3 Testing Information (All Models – Use With Section 8-10)
6 7
11
5 10 4 3
. CC/CV Model Shown
ST- 801 550 / SC-181 483-A
Y Discharge input capacitors accord- 4 Receptacle RC4 8 Voltage/Amperage Adjustment Control

ing to Section 9-3, and be sure volt- R2 (CC/CV Model) Or Amperage
Connection point for thermistor RT1.
age is near zero before touching any Adjustment Control R2 (CC Model)
parts. 5 Receptacle RC5
9 Inductance/Dig Control R44 (CC/CV
Be sure plugs are secure before testing. See Connection point for thermistor RT2. Model) Or Dig Control R44 (CC Model)
Section 8-10 for specific values during test-
6 Voltmeter V
ing. 10 Mode Switch S3
1 Display Board PC3 7 Ammeter A
11 Voltage/Amperage Control Switch S2
2 Receptacle RC1 . No calibration available for voltmeter V (CC/CV Model) Or Amperage Control
3 Receptacle RC2 or ammeter A. Switch S2 (CC Model)
TM-180 670 Page 40 XMT 304

8-10. Display Board PC3 Test Point Values (All Models)
a) Tolerance – ±10% unless
specified
PC3 Voltage Readings
b) Reference – to circuit common
(lead 42) unless noted
RC1 1 +24 volts dc input
2 Not used
3 +24 volts dc input
4 +1 volt dc input per 10 volts dc of weld output
5 –24 volts dc input
6 +15 volts dc input when HELP 1 screen is displayed, 0 volts dc during normal conditions
7 –24 volts dc input
8 0 to +10 volts dc output for dig/inductance
9, 10 Circuit common
11 –24 volts dc output with fan motor FM off, –10 volts dc output with fan motor FM on
12 Prior to Serial No. KG150087, circuit common; effective with Serial No. KG150087, 0 volts dc input
during normal operation, +15 volts dc input when HELP 8 screen is displayed
13 +15 volts dc output in Lift Arc mode
14 Prior to Serial No. KG150087, circuit common; effective with Serial No. KG150087, +15 volts dc input
during normal operation, 0 volts dc input when HELP 6 screen is displayed
15 +15 volts dc output with Mode switch S3 in Dig (SMAW) position, 0 volts dc output with S3 in GMAW
or GTAW position
16 Prior to Serial No. KG150087, circuit common; effective with Serial No. KG150087, +15 volts dc input
during normal operation, 0 volts dc input when HELP 7 screen is displayed
17 +15 volts dc output with output on, 0 volts dc output with output off
18 +15 volts dc output with Mode switch S3 in droop (SMAW) position, 0 volts dc output with S3 in remai-
ning positions
19 For CC/CV models only, +1.0 to +3.5 volts dc output, CV preset
20 +1 volt dc input per 100 amperes of weld output
21 +15 volts dc output with Mode switch S3 in CV position, 0 volts dc output with S3 in CC position (al-
ways 0 volts dc for CC models)
22 0 to +10 volts dc input from min to max of Voltage/Amperage Adjustment control R2 (CC/CV models)
or Amperage Adjustment control R2 (CC models); +13 volts dc in Pulse mode and weld output off
23 Prior to Serial No. KG150087, negative (–) voltage feedback input with respect to pin RC1-24;
24 Prior to Serial No. KG150087, positive (+) voltage feedback input with respect to pin RC1-23;
RC2 1 Prior to Serial No. KG150087, voltage feedback input with respect to pin RC2-6, same as positive (+)
weld output receptacle; effective with Serial No. KG150087, CC/CV select (+10 to +35 volts dc with
remote input indicates CV mode; 0 volts dc input indicates CC mode)
2 Circuit common
3 For CC/CV models, in MIG mode: +10 volts dc output; in all other modes: 0 to +10 volts dc output
from min to max of Voltage/Amperage Adjustment control R2.
4 +1 volt dc output per 100 amperes of actual or preset amperage output
5 115 volts ac input for weld output (On/Off)
6 Prior to Serial No. KG150087, voltage feedback input with respect to pin RC2-1, same as negative (–)
weld output receptacle; effective with Serial No. KG150087, circuit common (lead 42)
7 Reference common
8 24 volts ac input for weld output (On/Off)
9 +1 volt dc output per 10 volts dc of weld output
10 0 to +10 volts dc input command signal from min to max of remote control
RC4 1, 2 Approximately 33 k ohms at 68°F (20°C)
RC5 1, 2 Approximately 33 k ohms at 68°F (20°C)
XMT 304 TM-180 670 Page 41

8-11. Interconnecting Board PC2 Testing Information (All Models)
Y Discharge input capacitors
according to Section 9-3,
and be sure voltage is near
zero before touching any
parts.
. Be sure to use torque values in-

dicated on PC2 when servi-
cing. Use component-to-heat
sink torque value of 26 in-lb
when servicing SR1 and
IGBT’s PM1 and PM2.
. No test point values provided

for this PC board.
1 Interconnecting Board PC2
2 Receptacle RC1
3 Receptacle RC2
4 Receptacle RC3
2
4
ST-801 550 / 195 587
TM-180 670 Page 42 XMT 304

SECTION 9 – MAINTENANCE
9-1. Routine Maintenance
Y Disconnect power . Maintain more often

before maintaining. during severe conditions.
3 Months
Replace Repair Or
Damaged Or Replace Replace Cracked
Unreadable Cracked Torch Body
Labels Cables
Repair Or Replace
Cracked Cables
And Cords
Clean
And
Tighten Weld
Connections
6 Months
Blow Out Inside
9-2. Blowing Out Inside Of Unit

Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
ST-801 192
XMT 304 TM-180 670 Page 43

9-3. Measuring Input Capacitor Voltage
Y Significant DC voltage can
remain on capacitors after
unit is Off. Always check ca-
pacitors as shown to be sure
they have discharged before
working on unit.
Turn Off welding power source and
disconnect input power.
Remove case.
1 Input Capacitor C3 Terminals
3 Voltmeter
Check input capacitors as shown.
Measure the dc voltage across the
positive (+) and negative (–)
terminals until voltage drops to near
0 (zero) volts.
Proceed with job inside unit.
Reinstall case when finished.
1
3
Tools Needed:
5/16 in
ST-801 550
TM-180 670 Page 44 XMT 304

9-4. Checking Bus Voltage Imbalance
NOTE Check for a bus voltage imbalance whenever any of the following components are
replaced: capacitors C3 or C4; control board PC1; interconnecting board PC2;
IGBT power modules PM1 or PM2; or input rectifier SR1.
Y This procedure requires an

energized unit. Have only
personnel familiar with and
following standard safety
practices do the job.
Turn off welding power source.
Remove case.
4
3 Voltmeter
4 Receptacle 3/Plug 12
Measure the dc voltage across the
positive (+) and negative (–) termi-
nals on C3 and C4 as shown in Sec-
tion 9-3 until voltage drops to near
0 (zero) volts.
Prior to Serial No. KK266150, dis-
connect plug 12 from receptacle 3.
Connect two voltmeters across ca-
pacitors C3 and C4 as shown.
Place Process Selector switch in
Remote TIG position.
Turn on input power and monitor the
voltage levels across the capacitor
terminals. The bus voltages should
remain equal to each other 15%
(48 vdc maximum difference). If
the voltage difference exceeds the
15%, immediately turn off the
unit and repeat the entire Pre-Pow-
3 er Checklist. If the voltage remains
balanced for 10 seconds, place the
Process Selector Switch in the
SMAW position. If the voltage differ-
ence now exceeds the 15%, Im-
mediately turn off the unit and re-
peat the entire Pre–Power Check-
list.
3
Turn off unit and wait for voltage to
drop to near 0 (zero) volts accord-
ing to Section 9-3. Prior to Serial
No. KK266150, reconnect plug 12
to receptacle 3.
Reinstall case.
1 2
Tools Needed:
5/16 in
ST-801 523-A / ST-801 536
XMT 304 TM-180 670 Page 45

SECTION 10 – 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. To order a copy, proceed as follows:
Model Serial Or Style Number Circuit Diagram Wiring Diagram
XMT 304 KG139511 thru KG150086 SC-179 690 SD-179 691
KG150087 thru KK104770 SC-181 838-C SD-179 691
KK104771 and following SC-197 552 SD-195 874
Circuit Board PC1 KG139511 thru KG150086 D-178 570♦♦
KG150087 thru KH541060 SD-182 087♦♦
KH541061 thru KK104770 SD-188 073♦♦
KK104771 and following SD-193 758
Circuit Board PC2 KG139511 thru KG150086 B-173 591♦♦
KG150087 thru KH357759 SB-182 259♦♦
KH357759 thru KJ171291 SB-183 623♦♦
KJ171292 thru KK276102 SB-190 430♦♦
KK276103 and following SB-195 589
Circuit Board PC3 KG177169 thru KH523188 SD-183 331♦♦

(CC Models)
KH523189 and following SD-190 712
Circuit Board PC3 KG139511 thru KG150086 D-183 327♦♦

(CC/CV Models)
KG150087 thru KH357826 SD-181 491-A♦♦
KH357827 and following SD-190 709
Circuit Boards PC4, PC5 KG139511 thru KH391019 SA-173 599♦♦
KH391020 and following SA-188 015
Circuit Board PC6 KG150087 thru KH391014 SA-181 127♦♦
KH391015 and following SA-186 775
♦♦ Not included in this manual
TM-180 670 Page 46 XMT 304

SC-179 690
Figure 10-1. Circuit Diagram For XMT 304 Effective With Serial No. KG139511 Thru KG150086
XMT 304 TM-180 670 Page 47
SC-181 838-C
Figure 10-2. Circuit Diagram For XMT 304 Effective With Serial No. KG150087 Thru KK104770
TM-180 670 Page 48 XMT 304
197 552
Figure 10-3. Circuit Diagram For XMT 304 Effective With Serial No. KK104771 And Following
XMT 304 TM-180 670 Page 49
Figure 10-4. Wiring Diagram For XMT 304 Effective With Serial No. KG139511 Thru KK104770
TM-180 670 Page 50 XMT 304
SD-179 691
XMT 304 TM-180 670 Page 51

Figure 10-5. Wiring Diagram For XMT 304 Effective With Serial No. KK104771 And Following
TM-180 670 Page 52 XMT 304
SD-195 874
XMT 304 TM-180 670 Page 53

Figure 10-6. Circuit Diagram For Control Board PC1
Effective With Serial No. KK104771 And Following (Part 1 Of 3)
TM-180 670 Page 54 XMT 304
SD-193 758 (1 Of 3)
XMT 304 TM-180 670 Page 55

TM-180 670 Page 56 XMT 304
SD-193 758 (2 Of 3)
XMT 304 TM-180 670 Page 57

TM-180 670 Page 58 XMT 304
SD-193 758 (3 Of 3)
XMT 304 TM-180 670 Page 59

Figure 10-9. Circuit Diagram For Display Board PC3 (CC Models)
Effective With Serial No. KH523189 And Following
TM-180 670 Page 60 XMT 304
SD-190 712
XMT 304 TM-180 670 Page 61

Figure 10-10. Circuit Diagram For Display Board PC3 (CC/CV Models)
TM-180 670 Page 62 XMT 304
SD-190 709
XMT 304 TM-180 670 Page 63

SB-195 589
Figure 10-11. Circuit Diagram For Interconnecting Board PC2

Effective With Serial No. KK276103 And Following
188 015
Figure 10-12. Circuit Diagram For IGBT Boards PC4, PC5

TM-180 670 Page 64 XMT 304
SA-186 775
Figure 10-13. Circuit Diagram For Filter Board PC6 Effective With Serial No. KH391015 And Following
XMT 304 TM-180 670 Page 65

Notes
TM-180 670 Page 66 XMT 304

TM-180 670B September 2001
Processes
Multiprocess Welding
Description
Arc Welding Power Source
XMT 304
(400 Volt Models)
Eff w/KG139511 And Following
For OM-180 670 Revisions * Thru M
Visit our website at

www.MillerWelds.com
SECTION 11 – PARTS LIST FOR KG139511 AND FOLLOWING
801 605-E
Figure 11-1. Parts Assembly

TM-180 670 Page 68 XMT 304
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 11-1. Parts Assembly
. . . 1 . . . . . . . . . . . . . . +175 148 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 175 256 . . INSULATOR, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 178 551 . . INSULATOR, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . . . 195 585 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . . 179 309 . . LABEL, caution falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . HD1 . . . . . 156 313 . . TRANSDUCER, current 300A (Prior to KK104771) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 130 204 . . CONNECTOR & PINS (Prior to KK104771) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 175 142 . . BUS BAR, lem (Prior to KK104771) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 175 139 . . BUS BAR, output rectifier (Prior to KK104771) . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . HD1 . . . . . 189 567 . . TRANSDUCER, current 300A (Eff w/KK104771) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 183 046 . . CABLE, LEM (Eff w/KK104771) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 194 546 . . BUS BAR, lem (Eff w/KK104771) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 175 139 . . BUS BAR, output rectifier (Eff w/KK104771) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 181 853 . . INSULATOR, screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . D1,2 . . . . . 179 630 . . KIT DIODE, ultra fast recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . PC6 . . . . . 191 916 . . CIRCUIT CARD, filter board kit (Prior to KH391014) . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . PC6 . . . . . 185 697 . . CIRCUIT CARD, filter board (Eff w/KH391014) . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 187 146 . . BRACKET, mtg filter board (Eff w/KH391014) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 179 276 . . BUSHING, snap-in nyl 1.000 ID x 1.375mtg hole . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . C5,6 R1 . . . 175 194 . . RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . RT1,2 . . . . 173 632 . . THERMISTOR, NTC 30K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . . . 185 836 . . LABEL, warning exploding parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . +183 551 . . WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 604 176 . . RECEPTACLE, str dx grd 2P3W 15A 125V (with aux. power) . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 198 245 . . NUT, .750NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . CB1 . . . . . 161 078 . . CIRCUIT BREAKER, man reset 1P 7A 250VAC (with aux. power) . . . . 1
. . . 18 . . . . . CB1 . . . . . 089 807 . . CIRCUIT BREAKER, man reset 1P 2.5A 250VAC (without aux. power) 1
. . . 19 . . . . . CB2 . . . . . 083 432 . . CIRCUIT BREAKER, man reset 1P 10A 250VAC . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . 191 918 . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 186 440 . . BUSHING, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 198 246 . . WASHER, flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 179 625 . . CABLE, pwr 6mm 4/c 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident rear (order by model and serial number) . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 175 282 . . COVER, receptacle (with aux. power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . 175 138 . . BOX, louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . . . 192 853 . . BRACKET, mtg contactor/capacitor/PC Board . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . PC1 . . . . . 178 567 . . CIRCUIT CARD, control (Prior to KG150087) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . PC1 . . . . . 188 071 . . CIRCUIT CARD, control (Eff w/KG150087 thru KK104771) . . . . . . . . . . 1
. . . . . . . . . . PLG2 . . . . 115 092 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . PC1 . . . . . 193 756 . . CIRCUIT CARD, control (Eff w/KK104771 and on) . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . RC10 . . . . 166 679 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . T2 . . . . . . 183 261 . . TRANSFORMER, control 200/400VAC (without aux. power) . . . . . . . . . 1
. . . 28 . . . . . . T2 . . . . . . 195 829 . . TRANSFORMER, control 200/400VAC (with aux. power) . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . 183 549 . . BRACKET, mtg aux transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . +192 855 . . WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . 153 403 . . BUSHING, snap-in nyl .750 ID x 1.000mtg . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 32 . . . . . . . . . . . . . . . 177 547 . . BUSHING, snap-in nyl 1.125mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . CT1 . . . . . 175 199 . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . 025 248 . . STAND-OFF, insul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . C1 . . . . . 188 446 . . CAPACITOR, polyp film .5uf 900VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
XMT 304 TM-180 670 Page 69
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 11-1. Parts Assembly (Continued)
. . . 36 . . . . . C3,4 . . . . . 193 285 . . CAPACITOR, elctlt 2700uf 450VDC (Prior to KJ297193, kit includes
capacitors C3, C4 and mounting bracket part no. 193 288) . . . . . . . . . . 1
. . . 36 . . . . . C3,4 . . . . . 192 935 . . CAPACITOR, elctlt 2700uf 450VDC (Eff w/KJ297193) . . . . . . . . . . . . . . 2
. . . 37 . . . . . PC2 . . . . +185 090 . . CIRCUIT CARD, interconnect (Prior to KK276107)
(when ordering PC2, also order MOV protection board 198 095) . . . . . . 1
. . . . . . . . PLG14,15 . . 115 094 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 37 . . . . . PC2 . . . . . 197 585 . . CIRCUIT CARD, interconnect (Eff w/KK276107) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG14,21 . . 115 093 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . T3 . . . . . . 182 108 . . CHOKE, common mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . 175 140 . . BRACKET, DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . 175 482 . . COIL, DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 41 . . . . . . . . . . . . . . . 109 056 . . CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 42 . . . . . SR1 . . . . . 179 629 . . KIT DIODE, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . PM1,2 . . . . 180 110 . . KIT, transistor IGBT module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . Z1 . . . . . . 173 570 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . L1 . . . . . . 173 563 . . INDUCTOR, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . . 173 631 . . HEAT SINK, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . T1 . . . . . . 179 616 . . TRANSFORMER, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . . 175 192 . . HEAT SINK, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . . 175 255 . . INSULATOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 175 969 . . INSULATOR, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 181 197 . . GASKET, DI/DT rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . . 173 693 . . FOOT, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 51 . . . . . . . . . . . . . . . 176 736 . . SCREW, mtg foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 52 . . . . . . . . . . . . . . . 175 132 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . PC3 . . . . *178 518 . . CIRCUIT CARD, front panel display (CC/CV model)
(Prior to KG150087) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . PC3 . . . . *190 707 . . CIRCUIT CARD, front panel display (CC/CV model)
(Eff w/KG150087) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . PC3 . . . . *190 710 . . CIRCUIT CARD, front panel display (CC only model) . . . . . . . . . . . . . . . 1
. . . 54 . . . . . FM . . . . . 175 084 . . MOTOR, fan 24VDC 3000RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . RC1 . . . . . 175 217 . . RECEPTACLE, w/leads & plug (Prior to KG150087) . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . RC1 . . . . . 180 128 . . RECEPTACLE, w/leads & plug (Eff w/KG150087 thru KH357825) . . . . 1
. . . 55 . . . . . RC1 . . . . . 185 730 . . RECEPTACLE, w/leads & plug (Eff w/KH357826 and on) . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . . 178 548 . . TERMINAL, connector friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 57 . . . . . C7,8 . . . . . 186 543 . . CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 58 . . . . . . . . . . . . . . . 185 732 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . . 129 525 . . RECEPTACLE, twlk insul fem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 60 . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 070 590 . . TUBING, gl acryl .325 (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1ft
. . . . . . . . . . . . . . . . . . . . . 180 520 . . INSULATION, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 145 088 . . KIT, connection Dinse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . . 174 992 . . KNOB, pointer .840 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 62 . . . . . . . . . . . . . . . 175 855 . . DOOR, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . . 174 991 . . KNOB, pointer 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 64 . . . . . . . . . . . . . . . 176 226 . . INSULATOR, switch power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . S1 . . . . . 128 756 . . SWITCH, tgl 3PST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . . 179 310 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Prior to LB088400, individual seven segments can be replaced with Part No.186 914. Effective w/LB088400, displays
are soldered in and not replaceable. Replace with proper PCB assembly.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-180 670 Page 70 XMT 304
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
PRINTED IN USA  2001 Miller Electric Mfg. Co.

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TM-180 670B September 2001

Eff. w/Serial Number KG139511

Arc Welding Power Source

Visit our website at

Declares that the product: XMT 304

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC

Low Voltage Directive: 73/23/EEC

Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC

Electromagnetic compatibility (EMC) Product standard for arc welding equipment:

Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1989

Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989

Insulation coordination for equipment within low-voltage systems:

European Contact: Danilo Fedolfi, Managing Director

Means Warning! Watch Out! There are possible hazards

This group of symbols means Warning! Watch Out! possible

1-2. Servicing Hazards

HOT PARTS can cause severe burns.

FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

XMT 304 TM-180 670 Page 1

OVERUSE can cause OVER-

1-3. EMF Information

TM-180 670 Page 2 XMT 304

2-1. Manufacturer’s Warning Label Definitions

Warning! Watch Out! There are

+ + + 4.1 Wear hat and safety glasses.

+ 5 Become trained and read the

XMT 304 TM-180 670 Page 3

1 Warning! Watch Out! There

1 Warning! Watch Out! There

TM-180 670 Page 4 XMT 304

XMT 304 TM-180 670 Page 5

Output Circuit Breaker Remote On

Gas Tungsten Arc

Direct Current Protective Earth

Constant Current Constant Voltage Foot Control Line Connection

Three Phase Static

I1max Rated Maximum

TM-180 670 Page 6 XMT 304

3-2. Duty Cycle And Overheating

60% Duty Cycle

6 Minutes Welding 4 Minutes Resting

Ref. SA-178 651

XMT 304 TM-180 670 Page 7

va_curve1 4/95 – SA-178 652 / SA-178 653

TM-180 670 Page 8 XMT 304

loc_2 3/96 - ST-801 192

XMT 304 TM-180 670 Page 9

Y ARC WELDING can cause Electromagnetic Interference.

Total Cable (Copper) Length In Weld Circuit Not Exceeding*

100 ft (30 m)** 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft

2-2/0 2-3/0 2-3/0

2-2/0 2-3/0 2-3/0 2-4/0

+ 2-2/0 2-3/0 2-4/0 2-4/0

2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0

TM-180 670 Page 10 XMT 304

Socket* Socket Information

A 24 volts ac. Protected by circuit breaker CB2.

C Output to remote control; 0 to +10 volts dc, +10

H Voltage feedback; +1 volt dc per 10 output recep-