Miller XMT 450 CC/CV Owner's Manual
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Miller XMT 450 CC/CV Owner's Manual

Arc welding power source 400 volt ce
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OM-257220P
2016−10
Processes
Multiprocess Welding
Description
Arc Welding Power Source
R
XMT 450 CC/CV
(400 Volt Model) CE
File: MULTIPROCESS
For product information,
Owner's Manual translations,
and more, visit
www.MillerWelds.com

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  • Page 1 OM-257220P 2016−10 Processes Multiprocess Welding Description Arc Welding Power Source XMT 450 CC/CV (400 Volt Model) CE File: MULTIPROCESS For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 8 − GMAW/FCAW OPERATION ............8-1.
  • Page 5 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
  • Page 6 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number XMT 450 CC/CV 400V W/AUX POWER (CE) 907525 XMT 450 MPA 400V (CE) 907468 INVISION 450 MPA 400V W/AUX POWER (CE) 907524 ALUMAPOWER 450 MPA 400V W/AUX POWER (CE)

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 8 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 10: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage.

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Tenir les bouteilles éloignées des circuits de soudage ou autres LE BRUIT peut endommager l’ouïe. circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. Le bruit des processus et des équipements peut affecter l’ouïe. D Une électrode de soudage ne doit jamais entrer en contact avec D Porter des protections approuvées pour les une bouteille.

  • Page 14: Proposition Californienne 65 Avertissements

    RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de FRÉQUENCE (H.F.) risque provoquer des interférences. provoquer des interférences. D L’énergie électromagnétique risque D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences pour l’équipement provoquer des interférences avec les équi- électronique sensible tel que les ordinateurs et l’équipement commandé...

  • Page 15: Section 3 − Definitions

    A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste.
  • Page 16 A complete Parts List is available at www.MillerWelds.com Do not weld on drums or any closed containers. Safe16 2012−05 Do not remove or paint over (cover) the label. Safe20 2012−05 Disconnect input plug or power before working on machine. Safe30 2012−05 Flying pieces of parts can cause injury.
  • Page 17 A complete Parts List is available at www.MillerWelds.com Environmental Protection Use Period (China) Safe123 2016−06 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...

  • Page 18: Miscellaneous Symbols And Definitions

    A complete Parts List is available at www.MillerWelds.com 3-2. Miscellaneous Symbols And Definitions Gas Tungsten Arc Amperage Welding Alternating Current (AC) Positive Voltage Constant Voltage Shielded Metal Arc Welding (SMAW) Voltage Input Protective Earth Primary Voltage (Ground) Degree Of Line Connection Protection Three Phase Lift-Arc Trigger...

  • Page 19: Section 4 − Specifications

    A complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Features And Benefits LVCt Line Voltage Compensation is circuitry that keeps the power source output constant regardless of input pow- er fluctuation. Wind Tunnel Technologyt circulates air over components that require cooling, not over electronic circuitry, which reduces contaminants and improves reliability in harsh welding environments.

  • Page 20: Dimensions And Weight

    A complete Parts List is available at www.MillerWelds.com 4-5. Dimensions and Weight Hole Layout Dimensions 8-11/16 in. (221 mm) 11-3/8 in. (289 mm) 26.8 in. (681 mm) 15-3/4 in. (400 mm) 17.2 in. 22-7/16 in. (570 mm) (437 mm) 2-3/4 in. (70 mm) 3-3/8 in.
  • Page 21 A complete Parts List is available at www.MillerWelds.com C. China EEP Hazardous Substance Information   ‡ China EEP Hazardous Substance Information Ö Hazardous Substance Component Name × (if applicable) PBDE Ö Brass and Copper Parts Coupling Devices Switching Devices Ö...

  • Page 22: Duty Cycle And Overheating

    A complete Parts List is available at www.MillerWelds.com 4-7. Duty Cycle and Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool.

  • Page 23: Volt-Ampere Curves

    A complete Parts List is available at www.MillerWelds.com 4-8. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amper- age output capabilities of welding power source. Curves of other set- tings fall between curves shown. CC Mode STICK STICK REMOTE SCRATCH ARC CONTROL (DIG)

  • Page 24: Section 5 − Installation

    A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Selecting A Location Movement Do not move or operate unit where it could tip. Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 25: Selecting Cable Sizes

    **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. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-L 2015−02 5-3. Weld Output Terminals Turn off power before connecting to weld output terminals.

  • Page 26: Connecting Weld Output Cables

    A complete Parts List is available at www.MillerWelds.com 5-4. Connecting Weld Output Cables Do not place anything between weld cable terminal and copper bar. Incorrect Installation Tools Needed: 3/4 in. (19 mm) 803 778-B Weld Output Terminal output terminal and secure with nut so that Turn off power before connecting to weld cable terminal is tight against copper Supplied Weld Output Terminal Nut...

  • Page 27: 115 Volts Ac Duplex Receptacle And Supplementary Protectors

    A complete Parts List is available at www.MillerWelds.com 5-6. 115 Volts AC Duplex Receptacle And Supplementary Protectors 115 V 7 Amp AC Receptacle Supplementary Protector CB1 Supplementary Protector CB2 CB1 protects duplex receptacle. CB2 protects 24 volts AC portion of Remote receptacle from...

  • Page 28: Optional Gas Valve Operation And Shielding Gas Connection

    A complete Parts List is available at www.MillerWelds.com 5-7. Optional Gas Valve Operation And Shielding Gas Connection Obtain gas cylinder and chain to running gear, wall, or other station- ary support so cylinder cannot fall and break off valve. Cylinder Regulator/Flowmeter Install so face is vertical.

  • Page 29: Electrical Service Guide

    A complete Parts List is available at www.MillerWelds.com 5-8. Electrical Service Guide Elec Serv 2014−01 NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera- tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.

  • Page 30: Connecting Input Power

    A complete Parts List is available at www.MillerWelds.com 5-9. Connecting Input Power = GND/PE Earth Ground Tools Needed: 5/16 in. Input5 2013−04 / Ref. 803 766-C / 257 348-A OM-257220 Page 24...
  • Page 31 A complete Parts List is available at www.MillerWelds.com 5-9. Connecting Input Power (Continued) Supplied Cord) Connect input conductors L1, L2, and L3 to Turn Off welding power source, and welding power source line terminals. check voltage on input capacitors Select size and length of conductors using according to Section 10-3 before Section 5-2.

  • Page 32: Section 6 − General Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − GENERAL OPERATION 6-1. Front Panel 252 022-A / 256 366-A Arc Control Weld process operation sections de- The meters display the actual weld output scribe functionality of the identified items values after arc initiation and remains dis- Optional Gas Valve Knockout (See Sections 7-2 thru 9-3).

  • Page 33: Mode Switch Settings

    A complete Parts List is available at www.MillerWelds.com 6-2. Mode Switch Settings Switch Position Process Output Control Panel Adjust Remote Adjust Scratch Start TIG GTAW Electrode Hot Amps % Panel Amps Lift-Arc TIG GTAW Remote 14 Amps % Panel Amps Scratch Start TIG GTAW Remote 14...

  • Page 34: Section 7 − Gtaw Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − GTAW OPERATION 7-1. Typical Connection For GTAW Process 277777-A Remote 14 Receptacle Gas Out Connection (Optional) Turn off power before making con- nections. Connect desired remote control to Remote Negative (−) Weld Output Terminal 14 receptacle if required.

  • Page 35: Scratch Start Tig Welding Mode - Gtaw Process

    A complete Parts List is available at www.MillerWelds.com 7-2. Scratch Start TIG Welding Mode - GTAW Process 8 4.5 256 366-A Setup Operation Weld terminals are energized at all times in Scratch Start TIG welding For typical system connections refer to The Adjust Control is used to set desired mode.

  • Page 36: Lift-Arc Tig Welding Mode - Gtaw Process

    A complete Parts List is available at www.MillerWelds.com 7-3. Lift-Arc TIG Welding Mode - GTAW Process 256 366-A 1 − 2 “Touch” Seconds Do NOT Strike Like A Match! play. electrode. An arc will form when electrode Weld terminals energized is lifted.

  • Page 37: Remote Scratch Start Tig Welding Mode - Gtaw Process

    A complete Parts List is available at www.MillerWelds.com 7-4. Remote Scratch Start TIG Welding Mode - GTAW Process 256 366-A Setup Operation Weld terminals energized through the remote control in TIG For typical system connections refer to The Adjust Control is used to set desired welding mode.

  • Page 38: Section 8 − Gmaw/Fcaw Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 8 − GMAW/FCAW OPERATION 8-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process 277778-A Workpiece Use of shielding gas is dependant on Wire Turn off power before making Type. connections. Remote 14-Receptacle The connection diagram illustrates Wire Feeder DCEP (reverse polarity) suitable for all...

  • Page 39: Mig Welding Mode - Gmaw/Fcaw Process

    A complete Parts List is available at www.MillerWelds.com 8-2. MIG Welding Mode - GMAW/FCAW Process 2 5.0 256 366-A Rotate Mode Switch to MIG position as preset voltage on the welding power Weld terminals energized shown. source. through the remote control in MIG welding mode.

  • Page 40: Typical Connection For Remote Control Feeder Gmaw-P Process

    A complete Parts List is available at www.MillerWelds.com 8-3. Typical Connection For Remote Control Feeder GMAW-P Process Ref. 277779-A Workpiece Turn off power before making The connection diagram illustrates connections. DCEP (reverse polarity) suitable for all Wire Feeder Optima - External Pulsing Device wires except self-shielded FCAW.

  • Page 41: Pulsed Mig Welding Mode - Gmaw-P Process

    A complete Parts List is available at www.MillerWelds.com 8-4. Pulsed MIG Welding Mode - GMAW-P Process PP.P PPP 256 366-A Setup Operation Weld terminals energized through the remote control in This unit requires an external pulsing For typical system connections refer to Pulsed MIG welding mode.

  • Page 42: Typical Connection For Voltage-Sensing Feeder Gmaw/Fcaw Process

    A complete Parts List is available at www.MillerWelds.com 8-5. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process 277780-A Use of shielding gas is dependant on Wire Turn off power before making con- Type. nections. Gun Trigger Receptacle Positive (+) Weld Output Terminal The connection diagram illustrates Negative (−) Weld Output Terminal Wire Feeder...

  • Page 43: V-Sense Feeder Welding Mode - Gmaw/Fcaw Process

    A complete Parts List is available at www.MillerWelds.com 8-6. V-Sense Feeder Welding Mode - GMAW/FCAW Process 2 5.0 256 366-A Rotate Mode Switch to V-SENSE FEEDER Arc Control (Inductance) Weld terminals are energized at all position as shown. times in V-Sense Feeder welding Rotate Arc Control to select desired induc- mode.

  • Page 44: Section 9 − Smaw/Cac-A Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 9 − SMAW/CAC-A OPERATION 9-1. Typical Connection For SMAW And CAC-A Process 277781-A cutting torch to to positive weld output ter- Connect desired remote control to remote Turn off power before making con- minal.

  • Page 45: Remote Stick Welding Mode - Smaw/Cac-A Process

    A complete Parts List is available at www.MillerWelds.com 9-2. Remote Stick Welding Mode - SMAW/CAC-A Process Operation Arc Control (Dig) Weld terminals energized The Adjust Control is used to set desired through the remote control in Re- Rotate Arc Control to select desired dig set- preset amperage.

  • Page 46: Stick Welding Mode - Smaw/Cac-A Process

    A complete Parts List is available at www.MillerWelds.com 9-3. Stick Welding Mode - SMAW/CAC-A Process 8 4.5 256 366-A The open circuit voltage is shown in the Left Arc Control (Dig) Weld terminals are energized at all Display and the preset amperage is shown times in Stick welding mode.

  • Page 47: Optional Low Open Circuit Voltage (Ocv) Welding Modes

    A complete Parts List is available at www.MillerWelds.com 9-4. Optional Low Open Circuit Voltage (OCV) Welding Modes Low OCV Operation The unit can be optionally configured for low open circuit voltage (OCV) operation in Stick and Scratch Start TIG modes. When the unit is config- ured for low OCV operation only a low sensing voltage (approximately 15 VDC) is present between the electrode and the workpiece prior to the electrode touching the workpiece.

  • Page 48: Section 10 − Maintenance & Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 10 − MAINTENANCE & TROUBLESHOOTING 10-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. 3 Months Repair Or Replace Replace Cracked Replace Damaged Or Torch Body Cracked Unreadable Cables Labels...

  • Page 49: Removing Case And Measuring Input Capacitor Voltage In 400 Vac Models

    A complete Parts List is available at www.MillerWelds.com 10-3. Removing Case and Measuring Input Capacitor Voltage In 400 VAC Models Turn Off welding power source, and disconnect in- put power. Significant DC voltage can remain on capacitors after Typical Bleeder Resistor unit is Off.

  • Page 50: Help Displays

    A complete Parts List is available at www.MillerWelds.com 10-4. Help Displays All directions are in reference to the front of the unit. All circuitry referred to is lo- cated inside the unit. HE.L Help 1 Display Indicates a malfunction in the primary power circuit.
  • Page 51 A complete Parts List is available at www.MillerWelds.com Notes OM-257220 Page 45...

  • Page 52: Section 11 − Electrical Diagram

    SECTION 11 − ELECTRICAL DIAGRAM Figure 11-1. Circuit Diagram OM-257220 Page 46...
  • Page 53 256 909-B OM-257220 Page 47...
  • Page 54 Notes...
  • Page 55 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 56 Contact the Delivering Carrier to: 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2016 Miller Electric Mfg. Co. 2016−01...

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