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Multiprocess Welding
Description
XMT 425 VS
™
Auto-Line
Effective with Serial No. LJ400122A
File: MULTIPROCESS
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
INFORMATION ON OLDER UNITS
This manual includes operating information for current units. To obtain specific operating information for older models, download the applica-
ble Owner’s Manual from www.MillerWelds.com.
Effective with LK450041A, optional low open circuit voltage operation was added to the Scratch Start Tig mode.
Effective with ME100269U, IGBT Module Kit No. 217 625 was discontinued. See Parts List and Service Memo 1233 for additional information.
See the Miller Extranet for service memos that may aid in the repair of this product.
TABLE OF CONTENTS
Do not touch live electrical parts. Put on grounded wrist strap BEFORE handling
boards or parts.
Turn Off welding power source and wire feeder
and disconnect and lockout input power using Use proper static-proof bags and boxes to
line disconnect switch, circuit breakers, or by removing plug from re- store, move, or ship PC boards.
ceptacle, or stop engine before servicing unless the procedure spe-
cifically requires an energized unit. FIRE OR EXPLOSION hazard.
Do not work on equipment unless it has been verified that the ma- Do not place unit on, over, or near combustible
chine case is not energized. surfaces.
Insulate yourself from ground by standing or working on dry insulat- Do not service unit near flammables.
ing mats big enough to prevent contact with the ground.
Do not leave live unit unattended. FLYING METAL or DIRT can injure eyes.
If this procedure requires an energized unit, have only personnel Wear safety glasses with side shields or face
familiar with and following standard safety practices do the job. shield during servicing.
When testing a live unit, use the one-hand method. Do not put both Be careful not to short metal tools, parts, or
hands inside unit. Keep one hand free. wires together during testing and servicing.
Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source. HOT PARTS can burn.
SIGNIFICANT DC VOLTAGE exists in inverter weld- Do not touch hot parts bare handed.
ing power sources AFTER removal of input power. Allow cooling period before working on
equipment.
Turn off unit, disconnect input power, and discharge input capaci- To handle hot parts, use proper tools and/or wear heavy, insu-
tors according to instructions in Manual before touching any parts. lated welding gloves and clothing to prevent burns.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2017−04
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2017−04
Safe5 2017−04
Safe6 2017−04
Safe8 2012−05
Safe10 2012−05
Safe12 2012−05
Safe14 2012−05
Safe16 2017−04
Safe20 2017−04
Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.
Safe27 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
Safe29 2012−05
Safe31 2017−04
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Safe40 2012−05
= < 60° Always lift and support unit using both handles. Keep angle of lifting
device less than 60 degrees.
Use a proper cart to move unit.
Safe44 2012−05
S
Welding In An
Environment With
Increased Risk Of
Percent
I2 Rated Welding
Current
Pulse
U1 Input Voltage U0 Rated No−Load
Voltage (Average)
Power Connection Three Phase Stat-
ic Frequency
Converter-
IP Internal Protection
Rating
X Duty Cycle
Gas Output Read Instructions
On
I1max Rated Maximum
Supply Current
Gas Metal Arc
Welding (GMAW)
Notes
This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C).
Max. RMS Amps Input at Rated Load Output,
Input Voltage Amperage 60 Hz 3-Phase at NEMA Load Voltages
Open-
Rated Output Range in Range in and Class I Rating KVA KW
Power Circuit
CV Mode CC Mode
Voltage 208 V 230 V 400 V 460 V 575 V
350 A at 34 VDC,
3-Phase 10−38 V 5−425 A 75 VDC 40.4 36.1 20.6 17.8 14.1 14.2 13.6
60% Duty Cycle
*See Section 3-5 for Duty Cycle Rating.
B
71 lb (32.2 kg)
804 801-A
IP Rating
IP23
This equipment is designed for outdoor use.
IP23 2017−02
B. Temperature Specifications
500
425
400
WELDING AMPERES
350
300
THREE PHASE
250 OPERATION
200
150
100
10 15 20 25 30 40 50 60 70 80 90 100
% DUTY CYCLE
Overheating
0 A or V
15
OR
Minutes Reduce Duty Cycle
Ref. 219523-A
Notes
80
70
60
VOLTS
50 SMAW GTAW
MAX MAX
40
30 GTAW
SMAW
80A
MN
20 0% ARC
25% CONTROL
10 50%
75%
100%
0
0 100 200 300 400 500
AMPERAGE
B. CV Mode
100
90
80
70
60
VOLTS
50
MAX
40
30
20
MIN
10
0
0 100 200 300 400 5 00
AMPERAGE
217836-A / 217837-B
Notes
Movement
2 ! Do not move or operate unit
where it could tip.
OR 3
loc_med 2015-04
Notes
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60%
60 − 100%
Welding Duty 10 − 100% Duty Cycle
Duty Cycle
Amperes Cycle AWG (mm2)
AWG (mm2)
AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)
600 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.
Ref. S-0007-M 2017−08
NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input
voltage.
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be be available.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-
tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
60 Hz Three-Phase
Input Voltage (V) 208 230 400 460 575
Rated Maximum Supply Current I1max (A) 51.5 46.5 26.3 22.6 18
Maximum Effective Supply Current I1eff (A) 31.3 28.2 16 13.7 10.9
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2 45 40 25 20 15
Normal Operating Fuses 3 60 50 30 25 20
8 10 12 14 14
Min Input Conductor Size In AWG (mm2) 4
(8.4) (5.3) (3.3) (2.1) (2.1)
119 96 175 150 234
Max Recommended Input Conductor Length In Feet (Meters)
(36) (29) (53) (46) (71)
10 10 12 14 14
Min Grounding Conductor Size In AWG (mm2) 4
(5.3) (5.3) (3.3) (2.1) (2.1)
Notes
L1
3 L2 5
6 L3
Tools Needed:
! Installation must meet all National and voltage available at site. This unit can be con- 5 Input Conductors (L1, L2 And L3)
Local Codes − have only qualified per- nected to any input power between 208 and 6 Disconnect Device Line Terminals
sons make this installation. 575 VAC without removing cover to relink the
power source. Connect green or green/yellow grounding
! Disconnect and lockout/tagout input conductor to disconnect device grounding ter-
power before connecting input con- See rating label on unit and check input volt- minal first.
ductors from unit. Follow established age available at site.
procedures regarding the installation Connect input conductors L1, L2, and L3 to
and removal of lockout/tagout For Three-Phase Operation disconnect device line terminals.
devices. 7 Over-Current Protection
1 Input Power Cord.
! Always connect green or green/yellow 2 Disconnect Device (switch shown in the
Select type and size of over-current protec-
conductor to supply grounding termi- tion using Section 4-5 (fused disconnect
OFF position)
nal first, and never to a line terminal. switch shown).
3 Green Or Green/Yellow Grounding
NOTICE − The Auto-Line circuitry in this unit Conductor Close and secure door on disconnect device.
automatically adapts the power source to the Follow established lockout/tagout procedures
primary voltage being applied. Check input 4 Disconnect Device Grounding Terminal to put unit in service.
Input2 2012−05
Notes
1 Power Switch ing, place switch in Stick position. For best re- Select setting best suited for application.
sults, place Arc Control in the maximum posi-
The fan motor is thermostatically tion. Control adjusts inductance when V-Sense
controlled and only runs when cooling is 6 Arc Control Feeder position is selected on the mode
needed. switch. Inductance (0-100%) determines the
Control adjusts Dig when Stick mode is se-
2 Voltmeter “wetness” of the weld puddle. When set to-
lected on mode switch. When set towards
wards maximum, “wetness” (puddle fluidity)
3 Ammeter minimum, short-circuit amperage at low arc
increases.
4 V/A (Voltage/Amperage) Adjustment voltage is the same as normal welding
Control amperage. For self-shielding wires (FCAW) adjust arc
5 Mode Switch When set towards maximum, short-circuit control to FCAW setting.
amperage is increased at low arc voltage to
Mode switch setting determines the process. assist with arc starts as well as reduce stick- When one of the TIG modes is selected, this
For Air Carbon Arc (CAC-A) cutting and goug- ing while welding. control is not functional.
2 3 4
5 6
The meters display the actual weld output values for approximately three seconds after the arc is broken.
Stick mode provides the Adaptive Hot StartE 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.
V-Sense Feeder MIG (GMAW) With Voltage Sensing Wire Feeder Electrode Hot
Ref. S-156279
4 5 6
Boost Boost Inverter
Input Snubber Module
Inductor Inductor Mod2
L1 L2
7 8
Input 9
Snubber
Pre-Regulator Resistor Bus
Module Module Capacitors
Mod1 RM1 C12, C13
1 2 3
3 Phase Power 10
Input Switch Power Interconnect Board
Power S1 PC2 Current
Transformer
CT1
Bus Voltage
Input Rectifier Voltage
20
Front Panel And Display Board PC3
21 21
Voltmeter Ammeter
V A
22 23
Voltage/
Arc
Amperage
Control
Adjust
Ribbon Cable
24 25
Positive (+) Output Voltage Feedback
Process Weld
Selector Process Negative (−) Output Voltage Feedback
Switch Control
Work
16 17 18
Stick Stick Stick
Boost Boost Boost
Relay Inductor Rectifier
CR1 L4 SR1
15
11 12 13 14 Positive (+)
Series Main Output Weld
Capacitor Transformer Diodes Output
C15 T1 D1 & D2 Output Receptacle
Current
Sensor
HD1
Main Transformer Output Current Feedback
Current Feedback
27 28 Inverter
Control Control
Boost
Control Power
Supply 32 33
Secondary Primary
Control Board Heatsink Heatsink
PC1 Thermistor Thermistor
RT-1 RT-2
Control Circuit
Primary Circuit
Weld Circuit
♦ Optional
3 Power Interconnect Board PC2 Rectifies the main secondary output of T1. Contains the boost control, control power
14 Output Current Sensor HD1 supply, and inverter control.
Provides electrical connections for L1, L2,
MOD1, MOD2, RM1, C12 & C13. Prechar- Provides weld output current feedback to 27 Boost Control
ge and bleeder resistors and snubber ca- PC1.
pacitors are mounted on PC2. 15 Positive (+) and Negative (−) Weld Controls switching of boost IGBT in MOD1
Output Receptacles to regulate L1 current and the DC bus volt-
4 Boost Input Inductor L1 age.
Provide weld output and allow changing of
Required to boost input rectifier voltage to
output polarity. 28 Control Power Supply
bus voltage.
16 Stick Boost Relay CR1
5 Boost Snubber Inductor L2 Provides power for boost and inverter con-
Provides on/off control of Stick boost out- trol circuitry on control board PC1.
Required to ensure soft−switching of the put circuit.
boost IGBT located in MOD1. 17 Stick Boost Inductor L4 29 Inverter Control
6 Inverter Module MOD2 Limits current in the Stick boost output cir- Controls the main inverter and snubber
Contains the main inverter IGBTs, snubber cuit. IGBTs within MOD2. Regulates the weld
IGBTs, main boost diode, and two boost 18 Stick Boost Rectifier SR1 output current to the value received from
snubber diodes. weld process controller. Provides power to
Rectifies the Stick boost secondary output PC3. Drives fan motor and gas valve. Pro-
7 Input Pre−Regulator Module MOD1 of T1. vides interface between primary and sec-
19 Output Stabilizer L3 ondary thermistors and PC3.
Contains the input rectifier diodes, boost
IGBT, and one boost snubber diode. Filters or smooths the DC weld output cur- 30 Fan Motor FM1
rent.
8 Snubber Resistor Module RM1 Provides cooling of heatsinks and compo-
20 User Interface Board PC3
Contains one boost snubber resistor and nents mounted inside wind tunnel.
Consists of Voltmeter V, Ammeter A, Arc
one inverter snubber resistor.
Control, Voltage/Amperage Adjust, Re- The fan motor is thermostatically controlled
9 Bus Capacitors C12 & C13 mote 14−pin receptacle, Process Selector and only runs when cooling is needed.
Switch, and Weld Process Control. Once unit is cooled to proper temperature,
Stores energy and filters the DC bus volt-
21 Voltmeter V, Ammeter A fan will continue to run for ten minutes.
age for input boost and inverter.
See Sections 5-1, Front Panel Controls 31 Optional Gas Solenoid GS1
10 Current Transformer CT1 and 5-2, Meter Functions.
Provides T1 current feedback to PC1. 22 Arc Control Provides on/off flow of shielding gas to the
Used to protect inverter IGBTs in case of T1 arc while TIG welding.
primary overcurrent. Controls Dig in Stick process or Inductance
in MIG process. See Section 5-1, Front 32 Secondary Heatsink Thermistor RT-1
11 Series Capacitor C15 Panel Controls.
23 Voltage/Amperage Adjust Monitors temperature of secondary heat-
Provides protection against T1 saturation. sink for fan motor control and overtempera-
Saturation occurs when the voltage across Selects weld output voltage or amperage ture shutdown.
the transformer is not balanced. The unbal- level. See Section 5-1, Front Panel Con-
anced voltage appears as a DC offset volt- trols. 33 Primary Heatsink Thermistor RT-2
age across the transformer and can cause
T1 primary overcurrent. The capacitor pro- 24 Process Selector Switch Monitors temperature of primary heatsink
tects against this condition by blocking the Selects weld process. See Section 5-1, for fan motor control and overtemperature
DC offset. Front Panel Controls. shutdown.
Trouble1_2018-04
! Measure voltage of input capacitors according to Section 7-3 and be sure voltage is near zero before touching any parts.
! Before applying power to unit, complete the following checks to avoid causing further damage.
! Although control board PC1 and power interconnect board PC2 are briefly checked here, more complete tests may be
needed later for these parts. This procedure is simply to get a basic okay to power up unit.
See Section 7-19 for test points and values and Section 10 for parts location.
Use Miller Testing Booklet (Part No. 150853) when servicing this unit.
See the Miller Extranet for service memos that may aid in the repair of this product.
prepower 2018-08
Notes
4
1
3
1 2
2
Ref. 804714-A
AC3 L1
Input Pre-Regulator Module MOD1 IGBT Tester Positive Lead - RED IGBT Tester Negative Lead - BLACK Gate
Boost IGBT (w/Plug Removed From RC3) L1-L2 −BUS RC3-2
L2
Input Pre-Regulator Module MOD2 IGBT Tester Positive Lead - RED IGBT Tester Negative Lead - BLACK Gate
Inverter IGBT (w/Plug Removed From RC1) HF-XFMR −BUS RC1-6
Inverter IGBT (w/Plug Removed From RC1) +BUS HF-XFMR RC1-1
Snubber IGBT (w/Plug Removed From RC1) HF-XFMR D9 Left RC1-10
Snubber IGBT (w/Plug Removed From RC1) TP3 D9 Left RC1-9
XMT 425 VS TM-234202 Page 27
PRE-POWER CHECKS
7-8. Power Interconnect Board PC2
R1 R8
! Read and follow safety information applied to the machine. All other connecting screws torque to
in Section 7-2 before proceeding. (20 in. lbs (2.3 N.m)
1 Power Interconnect Board PC2 Visually inspect PC2 for damage.
! Wear an earth grounded wrist Check all measurements for PC2 (see
strap when performing pre-power 2 MOD1 And MOD2 Connecting Section 7-9).
and power off checks. Remove Screws
wrist strap before performing any Initial Torque to (9 in. lbs (1 N.m) If any measurements failed, replace
checks or procedures with power Final Torque to (20 in. lbs (2.3 N.m) PC2 and bus capacitors.
Notes
K A
1
D68 D22 D32 D36
K
D62
D58
D51 A
K
D20
D21
A
RC3
! Read and follow safety information checks or procedures with power Visually inspect PC1 for damage.
in Section 7-2 before proceeding. applied to the machine.
Check all measurements for PC1 Control
! Wear an earth grounded wrist Remove all plugs from PC1 before Power (see Section 7-11).
strap when performing pre-power
and power off checks. Remove
testing.
If any measurements failed, replace
wrist strap before performing any 1 Control Board PC1 PC1.
Notes
Diodes D1, D2
Ref. 804714-A / 804979-A
3 2
4 1
! Before connecting welding equipment to input (primary) power for servicing, be sure the input-power circuit protection is correct
for the welding equipment. Connect equipment to a dedicated circuit sized and fused for the rated output and duty cycle of the
welding equipment you are servicing. See the Electrical Service Guide section in this manual and National Electrical Code (NEC)
article 630, Electric Welders.
! Remove earth grounded wrist strap before performing any checks or procedures with power applied to the machine.
Equipment serviced may need to meet additional requirements as specified in IEC60974-4, Arc Welding Equipment − Part 4: Periodic
Inspection and Testing.
See Section 7-19 for test points and values and Section 10 for parts location.
Use MILLER Testing Booklet (Part No. 150853) when servicing this unit.
See the Miller Extranet for service memos that may aid in the repair of this product.
Trouble Remedy
No weld output; unit completely Place line disconnect switch in On position (see Section 4-6).
inoperative.
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-6).
Check for proper input power connections and check condition of power cord (see Section 4-6).
Check continuity of Power switch S1 and replace if necessary (see Section 7-12).
Check control board PC1 and connections, and replace if necessary (see Pre-Power Checks in Sec-
tions 7-22 thru 7-23, and also see Section 7-20).
Check power interconnect board PC2 and connections, and replace if necessary (see Pre-Power
Checks in Sections 7-26 thru 7-27, and also see Section 7-24).
Check front panel/display board PC3 and connections, and replace if necessary (see Section 7-30).
No weld output; meter display On. Check input and output voltages of hall device HD1 (see Section 7-19). Replace HD1 if necessary.
Check control board PC1 and connections, and replace if necessary (see Pre-Power Checks in Sec-
tions 7-22 thru 7-23, and also see Section 7-20).
Check front panel/display board PC3 and connections, and replace if necessary
(see Section 7-30).
Low weld output with no control. Check input and output voltages of hall device HD1 (see Section 7-19). Replace HD1 if necessary.
Check control board PC1 and connections, and replace if necessary (see Pre-Power Checks in Sec-
tions 7-22 thru 7-23, and also see Section 7-20).
Check front panel/display board PC3 and connections, and replace if necessary (see Section 7-30).
Maximum weld output with no control. Check input and output voltages of hall device HD1 (see Section 7-19). Replace HD1 if necessary.
Check control board PC1 and connections, and replace if necessary (see Pre-Power Checks in Sec-
tions 7-22 thru 7-23, and also see Section 7-20).
Check front panel/display board PC3 and connections, and replace if necessary (see Section 7-30).
Limited output and low open circuit Check for proper input and output connections
voltage (OCV).
Check input and output voltages of hall device HD1 (see Section 7-19). Replace HD1 if necessary.
Check control board PC1 and connections, and replace if necessary (see Pre-Power Checks in Sec-
tions 7-22 thru 7-23, and also see Section 7-20).
Check front panel/display board PC3 and connections, and replace if necessary (see Section 7-30).
Check if Low Open Circuit Voltage Welding Mode is enabled (see Section 7-33).
Trouble Remedy
Erratic or improper weld output. Use proper size and type of weld cable (see Section 4-2).
Replace electrode.
Check input and output voltages of hall device HD1 (see Section 7-19). Replace HD1 if necessary.
Check control board PC1 and connections, and replace if necessary (see Pre-Power Checks in Sec-
tions 7-22 thru 7-23, and also see Section 7-20).
Check front panel/display board PC3 and connections, and replace if necessary (see Section 7-30).
Fan motor does not run after approxi- Check and clear blocked fan blade
mately four minutes of operation at
rated load.
Check receptacle wiring and connections. Check thermistors RT-1 and RT-2 (see Section 7-19).
Fan motor FM1 starts and meters display HELP-2 when RT-1 or RT-2 is disconnected from PC1.
When RT-1 or RT-2 is reconnected, the meter displays change but the fan continues to run (see Sec-
tion 7-18).
Check fan motor FM (see Section 7-19) and replace fan motor if necessary.
Tungsten electrode oxidizing and not Shield weld zone from drafts.
remaining bright after conclusion of
weld. Increase postflow time.
V A
Help 2 Display
V A
Help 3 Display
HE.L P−3 Indicates the left side of the unit has over-
heated. The unit has shut down to allow the
fan to cool it (see Section 3-5). Operation will
continue when the unit has cooled.
V A
Help 5 Display
HE.L P−5 Indicates the right side of the unit has over-
heated. The unit has shut down to allow the
fan to cool it (see Section 3-5). Operation will
continue when the unit has cooled.
V A
Help 6 Display
V A
Help 8 Display
V A
Process Display
R7 R8
R4
V1 R9
V2
R6
V9
R3
R5
V6
V7
V8
Approx. 35K ohms
at 705 F (215 C) {
V3
V4
V5
254072-A
7-20. Control Board PC1 Testing Information (Use with Section 7-21)
! Measure voltage of input ca-
pacitors according to Sec-
tion 7-3, and be sure voltage
is near zero before touching
any parts.
Be sure plugs are secure before
applying power. See Section 7-21
for specific values during testing.
RC9 1 Control Board PC1
1
RC11
RC7
RC6
RC2
RC8
RC10
RC1 RC3
RC1
! Do not measure − high voltage present.
RC2
! High voltage present. Voltages on this receptacle can exceed 900 volts DC from chassis (GND).
NOTE: All pins on this receptacle are referenced to the primary − Bus
1 Input Primary (+) bus; regulated to 940 volts DC with respect to primary (−) bus.
2 Not used
3 Not used
RC3
! High voltage present. Voltages on this receptacle can exceed 900 volts DC from chassis (GND).
NOTE: All pins on this receptacle are referenced to the primary − Bus
1 Input Do not measure − Boost inductor current feedback; 1 volt DC per 16 amps of boost inductor current
2 Output +15 volts DC; regulated with respect to primary (−) bus
3 Output −12 volts DC; regulated with respect to primary (−) bus
9 Input Do not measure − Main transformer current sense CT; senses overcurrent in T1 transformer primary
11 Output Precharge relay coil return; 0 volts DC = relay contacts open, −12 volts DC = relay contacts closed with
respect to primary (−) bus.
12 Not used
RC6 1 Input Output reference; 1 volt DC per 42.5 amperes of weld output when machine is under load; when mode
switch in SCRATCH START TIG mode, adjust control set at minimum = 0 volts DC, adjust control set at
maximum = 10 volts DC
4 Input Fan control; 0 volts DC when fan off, 3.2 volts DC when fan on
6 Not Used
7 Boost relay coil return; +24 volts DC = relay contacts open, less than 1 volt DC = relay contacts closed
8 Gas valve coil return; +24 volts DC = valve closed (no gas flow), less than 1 volt DC = valve open
9 Input Fan control; +5 volts DC when fan off, 2.0 volts DC when fan on
10 Input Fan control; 0 volts DC when fan off, 3.2 volts DC when fan on
11 Output Main transformer overcurrent detect; 0.7 volts DC = OK, +5 volts DC = T1 primary OVERCURRENT =
HELP1
12 Not Used
15 Output Secondary side thermistor return; +.78 volts DC at 25°C thermistor temperature
17 Output Primary side thermistor return; +.78 volts DC at 25°C thermistor temperature
19 Output Foldback; decreases weld output if input bus voltage drops, 0 volts = OK, +15 volts DC 15Khz pwm
squarewave = foldback
2 Input Secondary side thermistor return; +.78 volts DC at 25°C thermistor temperature
2 Input Primary side thermistor return; +.78 volts DC at 25°C thermistor temperature
2 Not Used
RC10 1 Output 115 volts AC RMS with respect to RC10−2 = fan on, 0 volts AC RMS = fan off
2 Output 115 volts AC RMS with respect to RC10−1 = fan on, 0 volts AC RMS = fan off
2 Boost relay coil return; +24 volts DC = relay contacts open, less than 1 volt DC = relay contacts closed
4 Gas valve coil return; +24 volts DC = valve closed (no gas flow), less than 1 volt DC = valve open
Notes
K A
RC9 1
D22
RC10
K
D24
D13
A
U10 U7 U11
1 8
2 7
3 6
4 5
! Read and follow safety information checks or procedures with power Check all measurements for PC1 (see
in Section 7-2 before proceeding. applied to the machine. Section 7-23).
Remove all plugs from PC1 before If any of the measurements do not read
! Wear an earth grounded wrist testing. correctly, replace PC1.
strap when performing pre-power
and power off checks. Remove 1 Control Board PC1 Continue to the end of the pre-power
wrist strap before performing any Visually inspect PC1 for damage. checks.
7-24. Power Interconnect Board PC2 Testing Information (Use with Section 7-25)
! Measure voltage of input
capacitors according to
Section 7-3, and be sure
voltage is near zero before
touching any parts.
Be sure plugs are secure before
applying power. See Section
7-25 for specific values during
testing.
1 Power Interconnect Board
PC2
RC1
RC2
RC3
RC6
Ref. 258043-C / 804714-A
RC1
! Do not measure − high voltage present.
RC2
! High voltage present. Voltages on this receptacle can exceed 900 volts DC from chassis (GND).
NOTE: All pins on this receptacle are referenced to the primary − Bus
1 Output Primary (+) bus; regulated to 940 volts DC with respect to primary (−) bus
2 Not Used
3 Not Used
RC3
! High voltage present. Voltages on this receptacle can exceed 900 volts DC from chassis (GND).
NOTE: All pins on this receptacle are referenced to the primary − Bus
4 Input −12 volts DC; regulated with respect to primary (−) bus, −12 volts DC power to boost inductor current
sensor
7 Input Precharge relay coil return; 0 volts DC = relay contacts open, −12 volts DC = relay contacts closed with
respect to primary (−) bus
8 Input +15 volts DC; regulated with respect to primary (−) bus, +15 volts DC power to boost inductor current
sensor
RC6
! High voltage present. Voltages on this receptacle can exceed 900 volts DC from chassis (GND).
NOTE: All pins on this receptacle are referenced to the primary − Bus
1 Snubber resistor1; input boost snubber, located in resistor module mounted to primary heat sink
2 Not Used
3 Snubber resistor2; inverter snubber, located in resistor module mounted to primary heat sink
4 Snubber resistor1; input boost snubber, located in resistor module mounted to primary heat sink
5 Not Used
6 Snubber resistor2; inverter snubber, located in resistor module mounted to primary heat sink
Section 7-25. Power Interconnect Board PC2 Test Point Values (Continued)
! High voltage present. The following terminals are used to interconnect the main power circuit with the prima-
ry supply, and with power circuit components not soldered in the pcb. Voltages on this receptacle can exceed
900 volts DC from chassis (GND).
AC1 Power Primary AC mains phase 1; line voltage, measure with respect to AC2 or AC3
AC2 Power Primary AC mains phase 2; line voltage, measure with respect to AC1 or AC3
AC3 Power Primary AC mains phase 3; line voltage, measure with respect to AC1 or AC2
L1 Power Input boost inductor; rectified line voltage, measure with respect to (−) bus
L1-L2 Power Common point between input boost inductor and boost IGBT snubber inductor
C13 (+) Power (+) Bus; regulated to 940 volts DC with respect to (−) bus
Center Bus Power Bus capacitors center point; regulated to 470 volts DC with respect to (−) bus
Notes
MATERIAL THICKNESS REFERENCE CHART
Notes
7-26. Power Interconnect Board (PC2) - Power Off Checks (Prior To MB510232A)
K A
Center
−BUS Bus +BUS Q2 D11 D10
D8
R14 D9
D13
Q1
K A
D12 D1
R11 D2
R12
R10
AC1
D3
D4
AC2
AC3
! Read and follow safety information checks or procedures with power Visually inspect PC2 for damage.
in Section 7-2 before proceeding. applied to the machine.
Check all measurements for PC2
! Wear an earth grounded wrist Remove all plugs from PC2 before (see Section 7-27).
strap when performing pre-power
and power off checks. Remove
testing.
If any measurements failed, replace
wrist strap before performing any 1 Power Interconnect Board PC2 PC2.
7-27. Power Interconnect Board (PC2) - Power Off Checks (Prior To MB510232A)
Power Interconnect Board PC2 DMM Positive Lead DMM Negative Lead DMM Diode DMM Ohms
Pre-Charge Resistor R14 R14 Bottom R14 Top N/A 200
SCR Gate Resistor R10 R10 Left R10 Right N/A 10 - 16.5
SCR Gate Resistor R11 R11 Left R11 Right N/A 10 - 16.5
SCR Gate Resistor R12 R12 Left R12 Right N/A 10 - 16.5
Pre-Charge Diode D5 AC3 R14 Top 0.20 - 0.90 N/A
Pre-Charge Diode D6 AC2 R14 Top 0.20 - 0.90 N/A
Pre-Charge Diode D7 AC1 R14 Top 0.20 - 0.90 N/A
Boost Gate Protection Diode D12 D12 Anode D12 Cathode 0.20 - 0.90 N/A
Boost Gate Protection Diode D13 D13 Anode D13 Cathode 0.20 - 0.90 N/A
Inverter Gate MOSFET Q1 Q1-S (Source) Q1-D (Drain) 0.20 - 0.90 N/A
Inverter Gate MOSFET Q2 Q2-S (Source) Q2-D (Drain) 0.20 - 0.90 N/A
Inverter Gate Protection Diode D1 D1 Anode D1 Cathode 0.20 - 0.90 N/A
Inverter Gate Protection Diode D2 D2 Anode D2 Cathode 0.20 - 0.90 N/A
Inverter Gate Protection Diode D3 D3 Anode D3 Cathode 0.20 - 0.90 N/A
Inverter Gate Protection Diode D4 D4 Anode D4 Cathode 0.20 - 0.90 N/A
Snubber Gate Protection Diode D8 D8 Anode D8 Cathode 0.20 - 0.90 N/A
Snubber Gate Protection Diode D9 D9 Anode D9 Cathode 0.20 - 0.90 N/A
Snubber Gate Protection Diode D10 D10 Anode D10 Cathode 0.20 - 0.90 N/A
Snubber Gate Protection Diode D11 D11 Anode D11 Cathode 0.20 - 0.90 N/A
Notes
7-28. Power Interconnect Board (PC2) - Power Off Checks (Effective With MB510232A)
K A
Q2
D1
R14
D9
Q1
K A
D12 D2
R11
R12
R10
AC1
D3
AC2
AC3
! Read and follow safety information dures with power applied to the Visually inspect PC2 for damage.
in Section 7-2 before proceeding. machine.
Check all measurements for PC2
! Wear an earth grounded wrist Remove all plugs from PC2 before (see Section 7-29).
strap when performing power off
checks. Remove wrist strap before
testing.
If any measurements failed, replace
performing any checks or proce- 1 Power Interconnect Board PC2 PC2.
7-29. Power Interconnect Board (PC2) - Power Off Checks (Effective With MB510232A)
Power Interconnect Board PC2 DMM Positive Lead DMM Negative Lead DMM Diode DMM Ohms
Pre-Charge Resistor R14 R14 Bottom R14 Top N/A 200
SCR Gate Resistor R10 R10 Left R10 Right N/A 10 - 16.5
SCR Gate Resistor R11 R11 Left R11 Right N/A 10 - 16.5
SCR Gate Resistor R12 R12 Left R12 Right N/A 10 - 16.5
Pre-Charge Diode D5 AC3 R14 Top 0.20 - 0.90 N/A
Pre-Charge Diode D6 AC2 R14 Top 0.20 - 0.90 N/A
Pre-Charge Diode D7 AC1 R14 Top 0.20 - 0.90 N/A
Boost Gate Protection Diode D12 D12 Left D12 Right N/A 100k
Inverter Gate MOSFET Q1 Q1-S (Source) Q1-D (Drain) 0.20 - 0.90 N/A
Inverter Gate MOSFET Q2 Q2-S (Source) Q2-D (Drain) 0.20 - 0.90 N/A
Inverter Gate Protection Diode D2 D2 Left D2 Right N/A 100k
Inverter Gate Protection Diode D3 D3 Left D3 Right N/A 100k
Snubber Gate Protection Diode D9 D9 Left D9 Right N/A 100k
Notes
7-30. Front Panel/Display Board PC3 Testing Information (Use with Section 7-31)
! Measure voltage of input ca-
pacitors according to Sec-
tion 7-3, and be sure voltage
is near zero before touching
any parts.
Be sure plugs are secure before ap-
plying power. See Section 7-31 for
specific values during testing.
1 Front Panel Board PC3
RC2
RC1
RC1 1 Output Output reference; 1 volt DC per 42.5 amperes of weld output when machine is under load; when mode
switch in SCRATCH START TIG mode, adjust control set at minimum = 0 volts DC, adjust control set at
maximum = 10 volts DC
4 Output Fan control; 0 volts DC when fan off, 3.2 volts DC when fan on
6 Not Used
7 Boost relay coil return; +24 volts DC = relay contacts open, less than 1 volt DC = relay contacts closed
8 Gas valve coil return; +24 volts DC = valve closed (no gas flow), less than 1 volt DC = valve open
9 Output Fan control; +5 volts DC when fan off, 2.0 volts DC when fan on
10 Output Fan control; 0 volts DC when fan off, 3.2 volts DC when fan on
11 Input Main transformer overcurrent detect; 0.7 volts DC = OK, +5 volts DC = T1 primary OVERCURRENT =
HELP1
12 Not Used
15 Input Secondary side thermistor return; +.78 volts DC at 25°C thermistor temperature
17 Input Primary side thermistor return; +.78 volts DC at 25°C thermistor temperature
19 Input Foldback; decreases weld output if input bus voltage drops, 0 volts = OK, +15 volts DC 15Khz pwm
squarewave = foldback
21 Input +24 volts DC, unregulated DC voltage with respect to GND, power feed to front panel pcb
22 Input +24 volts DC, unregulated DC voltage with respect to GND, power feed to front panel pcb
23 Input −24 volts DC, unregulated DC voltage with respect to GND, power feed to front panel pcb
24 Input −24 volts DC, unregulated DC voltage with respect to GND, power feed to front panel pcb
RC2 1 Input Negative weld output terminal; used for output voltage feedback
2 Not Used
3 Input Positive weld output terminal; used for output voltage feedback
Ref. 803728-B
Notes
Replace
Damaged Replace Cracked
Or Torch Body
Unreadable
Labels
Repair Or
Replace
Cracked
Cables
Every
3
Months
Repair Or Replace
Cracked Cables And
Cords
Clean
And
Tighten Weld
Connections
Every
6 Blow Out Inside
Months
803728-B
Tools Needed:
1/2, 9/16 in.
Start Your Professional 400 Trade Square East, Troy, Ohio 45373
Over 80,000 trained
Welding Career Now! 1-800-332-9448 www.welding.org since 1930!
TM-234202 Page 60 XMT 425 VS
SECTION 9 − 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 of all diagrams for models covered by this manual.
Multiprocess Welding
Description
XMT 425 VS
™
Auto-Line
Eff w/Serial No.
LJ400122A Thru MC450892U
For OM-234202 Revisions C Thru G
TM-234202 Page 76
6 15
16
25
5 76
13 19 30
9 31
20
4 26
17
10 18
3 33
74 35
71 36
75 32
22
72 37
21 38
54 53
39
40
59 41
60
47 17
1 52 MOD 2 43
2
61 46
MOD 1
62 48 45
55
58
LJ400122A THRU MC450892U
49
70
50
51
64
66
SECTION 10 − PARTS LIST FOR SERIAL NO.
67
68
69
Ref. 803729-K
XMT 425 VS
Eff w/Serial No. LJ400122A Thru MC450892U
Item Dia. Part
No. Mkgs. No. Description Quantity
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-234202 Page 78 XMT 425 VS
TM-234202L 2018−10
Eff w/Serial Number LJ400122A
Processes
Multiprocess Welding
Description
XMT 425 VS
™
Auto-Line
Eff w/Serial No.
MC450893 Thru MH424138U
For OM-234202 Revisions H Thru N
TM-234202 Page 80
24 27
8 74
12 15 16 23
19 30
5 9 77 25
20 31
4
3 26
76
18 17
10
75 35 33
72 36
32
73
37 38
22
53 39
54
21
40
61 60 41
1 59 17 43
52 47 MOD 2
2 62
MOD 1
46
44
71 42
58
49
SECTION 11 − PARTS LIST FOR SERIAL NO.
51
67 65 50
68
69
70
803729-P
XMT 425 VS
Eff w/Serial No. MC450893U Thru MH424138U
Item Dia. Part
No. Mkgs. No. Description Quantity
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
XMT 425 VS TM-234202 Page 81
Eff w/Serial No. MC450893U Thru MH424138U
Item Dia. Part
No. Mkgs. No. Description Quantity
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-234202 Page 82 XMT 425 VS
Eff w/Serial No. MC450893U Thru MH424138U
Item Dia. Part
No. Mkgs. No. Description Quantity
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Notes
Multiprocess Welding
Description
XMT 425 VS
™
Auto-Line
Eff w/Serial No.
MH424139U And Following
For OM-234202 Revision P
TM-234202 Page 86
6 15
16 23
25
73
5 9
13 72
4 19
74 29
10
20 26
17
18
2
3 70 31
71 32
67 33
30
22
68 34
48 21 35
49
36
37
55 38
56 47
43 17
1 39
54
57 42
58 50 44 41
53 45
66
46
60
SECTION 12 − PARTS LIST FOR SERIAL NO.
62
63
64
65
803729-Q
XMT 425 VS
Eff w/Serial No. MH424139U And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
XMT 425 VS TM-234202 Page 87
Eff w/Serial No. MH424139U And Following
Item Dia. Part
No. Mkgs. No. Description Quantity
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-234202 Page 88 XMT 425 VS
Notes
Miller Electric Mfg. LLC
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
For International Locations Visit
www.MillerWelds.com
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2018 Miller Electric Mfg. LLC 2018−01