Miller Electric XMC 4000 Owner's Manual
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Miller Electric XMC 4000 Owner's Manual

Miller Electric XMC 4000 Owner's Manual

Arc welding power source
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OM-221 694B
2006−07
Processes
Multiprocess Welding
Description
Arc Welding Power Source
XMC 4000
R
400 Volts

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Summary of Contents for Miller Electric XMC 4000

  • Page 1 OM-221 694B 2006−07 Processes Multiprocess Welding Description Arc Welding Power Source XMC 4000 400 Volts...
  • Page 2 Warranty and service information for your particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.

  • Page 3: Table Of Contents

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Manufacturer: ITW Welding Products Italy S.r.l. Via Privata Iseo 6/E 20098 San Giuliano Milanese, Italy Phone: 39(02)98290-1 European Contact Signature: Declares that this product: conforms to the following Directives and Standards: Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC and their amendments 91/368/EEC, 93/C 133/04, 93/68/EEC...

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment.
  • Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard F4.1 from Global...

  • Page 9: Section 2 − Definitions

    SECTION 2 − DEFINITIONS 2-1. Manufacturer’s Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock 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.
  • Page 10 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Hazardous voltage remains on input capacitors after power is turned off. Do OM-221 694 Page 6 >...
  • Page 11 Warning! Watch Out! There are possible hazards as shown by the symbols. Disconnect input plug or power before working on machine. 100 h. std. (B) 050024004 Wear approved safety glasses with side shields while working on the unit. Plugged filter or hoses can cause overheating to the power source and torch.

  • Page 12: Manufacturer's Rating Labels

    2-2. Manufacturer’s Rating Labels 2-3. Symbols And Definitions Amperage Remote Line connection Constant Voltage Constant Current Three Phase Static Frequency Con- verter- Transformer- Rectifier Primary Voltage 1max Conventional Load Voltage Rated No Load Voltage (Average) Pulsed OM-221 694 Page 8 Three Phase Gas Tungsten Arc Welding...

  • Page 13: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Specifications Rated Welding Voltage Amperage Output Output Range Range Range Range 300 A @ 32 Volts DC, 10 − 35 5 − 400 60% Duty Cycle *While idling 3-2. Duty Cycle And Overheating 6 Minutes Welding Overheating Amperes Input Maximum...

  • Page 14: Volt-Ampere Curves

    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 OM-221 694 Page 10...

  • Page 15: Selecting A Location

    3-4. Selecting A Location Dimensions And Weight 96.2 kg 1000 mm 813 mm 483 mm Location 500 mm 500 mm Movement Y Do not move or operate unit where it could tip. 500 mm 500 mm Lifting Handles Do not use handle to lift unit. Rating Label Use label to determine input power needs.

  • Page 16: Weld Output Terminals And Selecting Cable Sizes

    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.

  • Page 17: Circuit Breakers

    Coolant No. 043 809**; Distilled Or Deionized Water OK Above 32 F (0 C) Circuit breakers with numbers 7 and 10 are placed inside the welder on the wire feeder side as shown. Circuit Breaker 7 Protects the auxiliary 115 volt AC...

  • Page 18: Electrical Service Guide

    3-9. 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 Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes Normal Operating Min Input Conductor Size In mm Max Recommended Input Conductor Length In Meters...

  • Page 19: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Front Panel Controls ON/OFF Switch (I/O) Use switch to turn unit On/Off. MIG Gun Connector Positive gun connection for MIG or elec- trode holder for Stick Electrode Positive welding process, or work clamp connec- tion for TIG welding process. Work Connector Work clamp connection for MIG or Stick Electrode Positive welding process, or...

  • Page 20: Switching On The Unit And Recalling Factory Parameters

    4-2. Switching On the Unit and Recalling Factory Parameters 4-3. Welding Process Selection L1 LED L2 LED L3 LED L4 LED P3 Push Button Press P3 until desired process LED illumi- nates. Values and parameters that appear on D1 and D2 are either factory default settings or last settings entered for the selected pro- cess.

  • Page 21: Wire Type Selection In Synergic Mig Or Synergic Pulsed Mig Welding

    4-4. Wire Type Selection In Synergic MIG Or Synergic Pulsed MIG Welding L5 LED L6 LED L7 LED L8 LED P4 Push Button Press P4 until desired material LED illumi- nates. D1 and D2 will show material name only momentarily, and then return to the main display.

  • Page 22: Trigger Mode Selection

    4-6. Trigger Mode Selection Always check and set a trigger mode. If trigger mode is undefined for a weld- ing process, select the desired mode. L13 LED L14 LED L15LED L16 LED P6 Push Button Trigger mode can be set for TIG, Manual MIG, Synergic MIG, and Synergic Pulsed MIG welding to change when weld output power is present at the weld connnectors.

  • Page 23: Inductance, Material Thickness, And Gas Selection In Manual Mig, Synergic Mig, And Synergic Pulsed

    4-7. Inductance, Material Thickness, And Gas Selection In Manual MIG, Synergic MIG, And Synergic Pulsed MIG Incorrect settings in any process can result in a program with undesirable weld characteristics. Settings should only be changed by operators familiar with various welding processes and parameters.

  • Page 24: Setting And Using Weld Parameters From Memory

    4-9. Setting And Using Weld Parameters From Memory 4-10. Setup Push Button And Advanced Programming Press P2 to enter SET UP menu. SET UP will appear on D1 and D2 only mo- mentarily and then change to the selected process parameter values. Setup allows viewing and changing default parameter values for all welding processes for the desired weld characteristics.

  • Page 25: Preparing Unit For Mig Welding

    4-11. Preparing Unit For MIG Welding To select MIG welding process, proceed as follows: Follow safety precautions according to Section 1. Prepare unit according Section 3. Using a cable with a proper adapter, con- nect gun to the MIG gun connector. Connect work clamp cable to the WORK connector.

  • Page 26: Manual Mig Welding Advanced Settings

    4-13. Manual MIG Welding Advanced Settings To change all values list, unit must be MENU FULL. To set unit to MENU FULL, proceed as follows: Press P2 to enter SET UP menu. Select MENU FULL on D1 and D2 (see Section 4-10).

  • Page 27: Synergic Mig Welding Advanced Settings

    4-15. Synergic MIG Welding Advanced Settings To change all values list, unit must be MENU FULL. To set unit to MENU FULL, proceed as follows: Press P2 to enter SET UP menu. Select MENU FULL on D1 and D2 (see Section 4-10).

  • Page 28: Preparing Unit For Synergic Pulsed Mig Welding

    4-16. Preparing Unit For Synergic Pulsed MIG Welding Set Synergic Pulsed MIG welding process using P3 push button. Synergic Pulsed MIG welding is a high quality welding process that produces very little spatter. This process works well on thin metals such as stainless steel and alu- minum.

  • Page 29: Synergic Pulsed Mig Welding Advanced Settings

    4-17. Synergic Pulsed MIG Welding Advanced Settings To change all values list, unit must be MENU FULL. To set unit to MENU FULL, proceed as follows: Press P2 to enter SET UP menu. Select MENU FULL on D1 and D2 (see Section 4-10).

  • Page 30: Preparing Unit For Tig Welding

    4-18. Preparing Unit For TIG Welding To select TIG welding process, proceed as follows: Follow safety precautions according to Section 1. Prepare unit according Section 3. Connect torch to the WORK connector. Using a cable with a proper adapter, con- nect work clamp cable to the MIG gun con- nector.

  • Page 31: Tig Lift-Arc Welding

    4-20. TIG Lift-Arc Welding “Touch” Do NOT Strike Like A Match! 4-21. Preparing Unit For Stick Welding To select STICK welding process, proceed as follows: Follow safety precautions according to Section 1. Prepare unit according Section 3. Using a cable with a proper adapter, con- nect electrode holder to the MIG gun con- nector.

  • Page 32: Section 5 − Maintenance & Troubleshooting

    SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Replace Damaged Or Unreadable Labels 5-2. Blowing Out Inside Of Unit OM-221 694 Page 28 Y Disconnect power before maintaining. 3 Months Clean And Tighten Weld Terminals 6 Months Clean Drive Rolls Maintain more often during severe conditions.

  • Page 33: Circuit Breakers Cb7 And Cb10

    5-3. Circuit Breakers CB7 And CB10 Circuit Breaker CB7 Protects 115 volts ac power supply to water cooler from overload. If CB7 opens, water cooler stops op- erating. Circuit Breaker CB10 Protects 24 volts ac power supply to wire feeder from overload. If CB10 opens, wire feeding stops.

  • Page 34: Troubleshooting

    5-4. Troubleshooting Trouble No weld output: unit completely inopera- Place line disconnect switch in On position (see Section 3-9). tive tive. 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). No weld output;...

  • Page 35: Help Displays

    5-5. Help Displays HELP HELP HELP HELP HELP HELP HELP HELP HELP HELP HELP HELP OM-221 694 Page 31...
  • Page 36 All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Help 0 Indicates shorted thermistor RT2 on left side of unit. Contact a Factory Authorized Ser- vice Agent. Help 1 Indicates a malfunction in the primary power circuit.

  • Page 37: Section 6 − Electrical Diagram

    SECTION 6 − ELECTRICAL DIAGRAM January 26, 2005 OM-221 694 Page 33...

  • Page 38: Section 7 − Parts List

    SECTION 7 − PARTS LIST Hardware is common and not available unless listed. February 11, 2005 Figure 8-1. Unit Outer Assembly OM-221 694 Page 34...
  • Page 39 Item Dia. Part Mkgs..... . . 000151187 ..... V16122015 .
  • Page 40 Hardware is common and not available unless listed. February 11, 2005 Figure 8-2. Unit Main Assembly OM-221 694 Page 36...
  • Page 41 Item Dia. Part Mkgs. Figure 8-2. Unit Main Assembly ..CR5,6,R1 . . . 0001751940 ..D1,2 ..000201531 ..
  • Page 42 Notes...
  • Page 43 Effective January 1, 2006 This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, ITW Welding Products Italy S.r.l., warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
  • Page 44 File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2006 Miller Electric Mfg. Co. 1/06 TW Welding Products Italy S.r.l. Via Privata Iseo, 6/E 20098 San Giuliano Milanese, Italy...

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