Miller Electric XMS 4000 Owner's Manual
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Miller Electric XMS 4000 Owner's Manual

Miller Electric XMS 4000 Owner's Manual

Arc welding power source
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OM-224 043B
2006−07
Processes
Multiprocess Welding
Description
Arc Welding Power Source
XMS 4000
R
400 Volts

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Summary of Contents for Miller Electric XMS 4000

  • Page 1 OM-224 043B 2006−07 Processes Multiprocess Welding Description Arc Welding Power Source XMS 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

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 Via Privata Iseo 6/E 20098 San Giuliano Milanese, Italy Phone: 39(02)98290-1 European Contact Signature: XMS 4000 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, 92/31/CEE, 133/04, 93/68/EEC Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: Augusst1995...

  • 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 OM-224 043 Page 6 > 60 s 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.
  • 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 Three Phase Static Frequency Con- verter- Transformer- Rectifier Primary Voltage 1max Conventional Load Voltage Rated No Load Voltage (Average) Symbols not shown here are detailed in this manual when they are relevant. OM-224 043 Page 8 Voltage Three Phase...

  • 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 A. CC Mode ARC CONTROL 3-4. Installing Turntable for Wire Feeder on Power Source (Optional) OM-224 043 Page 10 Volt-ampere curves show minimum and maximum voltage and amper- age output capabilities of unit. Curves of other settings fall be- tween curves shown.

  • Page 15: Selecting A Location

    3-5. Selecting A Location Dimensions and Weight 86 kg 1020 mm 830 mm 490 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

    3-6. 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

    Y Use of any coolant other than those listed in the table voids the warranty on any parts that come in contact with the coolant (pump, radiator, etc.). Circuit breakers with numbers 7 and 10 are placed inside the welder on the wire feeder side as shown. Circuit Breaker 7...

  • Page 18: Electrical Service Guide

    3-10. 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. Fan is thermostatically controlled and runs only when necessary (Fan On Demand). Water cooling is automatically con- trolled and runs only when necessary. (Cooling On Demand).

  • 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: Gas Selection In Synergic Mig Or Synergic Pulsed Mig Welding

    4-6. Gas Selection in Synergic MIG or Synergic Pulsed MIG Welding L13 LED L14 LED L15 LED L16 LED P6 Push Button Press P6 until gas LED illuminates. D1 and D2 will show gas name momentarily and 4-7. Trigger Mode Selection (TIG and STICK Only) Always check and set a trigger mode.

  • Page 23: Setting And Using Weld Parameters From Memory (Tig And Stick Only)

    4-8. Setting And Using Weld Parameters From Memory (TIG and STICK Only) 4-9. 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.

  • Page 24: Preparing Unit For Mig Welding

    4-10. 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 the proper cable bundle, connect unit to the wire feeder (see Wire Feeder manual).

  • Page 25: Selecting Synergic Mig Welding

    4-12. Selecting Synergic MIG Welding Set Synergic MIG welding process using P3 push button. In Synergic MIG mode, the operator may need to adjust welding data (wire type, wire diameter, and gas type) and only one weld parameter. Generally, wire feed speed is adjusted and the synergic process auto- matically sets appropriate weld voltage.

  • Page 26: Selecting Synergic Pulsed Mig Welding

    4-13. Selecting 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 27: Preparing Unit For Tig Welding

    4-14. 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 3 and the gas pipe to the gas connector 5. Using a cable with a proper adapter, con- nect work clamp cable to the MIG gun con- nector.

  • Page 28: Tig Lift-Arc Welding

    4-15. TIG Lift-Arc Welding “Touch” Do NOT Strike Like A Match! 4-16. Preparing Unit For Stick Welding To select STICK welding process, proceed as follows: Follow safety precautions according to Section 1. Prepare unit according to Section 3. Connect electrode holder to the Positive power connector 2.

  • Page 29: Section 5 − Maintenance & Troubleshooting

    SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Replace Damaged Or Unreadable Labels Blow Out Inside Y Disconnect power before maintaining. 3 Months Repair Or Replace Cracked Cables 6 Months Blow Out Heat Exchanger Fins 12 Months Change Coolant (If Using MILLER Coolant) Maintain more often during severe conditions.

  • Page 30: Blowing Out Inside Of Unit

    5-2. Blowing Out Inside Of Unit 5-3. Help Displays 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.

  • Page 31: Troubleshooting

    5-4. Troubleshooting Trouble No weld output: unit completely inopera- Place line disconnect switch in On position (see Section 3-10). tive tive. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-10). Check for proper input power connections (see Section 3-10). No weld output;...
  • Page 32 Notes OM-224 043 Page 28...

  • Page 33: Section 6 − Electrical Diagram

    SECTION 6 − ELECTRICAL DIAGRAM May 9, 2005 OM-224 043 Page 29...

  • Page 34: Section 7 − Parts List

    SECTION 7 − PARTS LIST Hardware is common and not available unless listed. May 11, 2005 Figure 7-1. Unit Outer Assembly OM-224 043 Page 30...
  • Page 35 Item Dia. Part Mkgs..... . V57038158 ....+V17031141 .
  • Page 36 Hardware is common and not available unless listed. May 11, 2005 Figure 7-2. Unit Main Assembly OM-224 043 Page 32...
  • Page 37 Item Dia. Part Mkgs. Figure 7-2. Unit Main Assembly ..CR5,6,R1 ..000175940 ..... . 000199840 .
  • Page 38 Notes...
  • Page 39 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 40 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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