Miller XMT 450 CC Technical Manual
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Miller XMT 450 CC Technical Manual

Miller XMT 450 CC Technical Manual

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TM-257 220B
2015−03
Eff w/Serial Number MC100104A
Processes
Multiprocess Welding
Description
Arc Welding Power Source
R
XMT 450 CC/CV
(400 Volt Model) CE
File: MULTIPROCESS
Visit our website at
www.MillerWelds.com

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  • Page 1 TM-257 220B 2015−03 Eff w/Serial Number MC100104A Processes Multiprocess Welding Description Arc Welding Power Source XMT 450 CC/CV (400 Volt Model) CE File: MULTIPROCESS Visit our website at www.MillerWelds.com...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING ........1-1.
  • Page 3 TABLE OF CONTENTS SECTION 10 − TROUBLESHOOTING ............10-1.

  • Page 5: Section 1 − Safety Precautions For Servicing

    D Follow the guidelines in the Applications Manual for the Revised surfaces. NIOSH Lifting Equation (Publication No. 94−110) when manu- D Do not service unit near flammables. ally lifting heavy parts or equipment. XMT 450 CC/CV TM-257 220 Page 1...

  • Page 6: California Proposition 65 Warnings

    2. Do not place your body between welding cables. Arrange cables If cleared by your doctor, then following the above procedures is recom- to one side and away from the operator. mended. TM-257 220 Page 2 XMT 450 CC/CV...

  • Page 7: Section 2 − Definitions

    Safe10 2012−05 Keep flammables away from welding. Do not weld near flammables. Safe12 2012−05 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Safe14 2012−05 XMT 450 CC/CV TM-257 220 Page 3...
  • Page 8 Become trained and read the instructions before working on machine. Safe35 2012−05 Connect Green Or Green/Yellow grounding conductor to ground terminal first. Connect input conductors (L1, L2, L3) to line terminals. Safe36 2012−05 TM-257 220 Page 4 XMT 450 CC/CV...

  • Page 9: Miscellaneous Symbols And Definitions

    Supply Current Negative Primary Voltage Panel Inductance Degree Of Protection Alternating Current (AC) Foot Control Lift-Arc Trigger Hold Operation (GTAW) Voltage Gas Metal Arc Maximum Effec- Welding (GMAW) tive Supply Cur- 1eff rent XMT 450 CC/CV TM-257 220 Page 5...

  • Page 10: Section 3 − Specifications

    450 A @ 38 Volts DC, 100% 15 − 600 10 − 38 32.6 32.1 21.5 22.3 19.1 19.2 Phase Duty Cycle (0.42*) (0.47*) (0.28*) (0.32*) (0.07*) (0.07*) *While idling with fan on Notes TM-257 220 Page 6 XMT 450 CC/CV...

  • Page 11: Dimensions And Weight

    2,172,158 VA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the system impedance complies with the impedance restrictions. ce-emc 1 2014-07 TM-257 220 Page 7 XMT 450 CC/CV...

  • Page 12: Duty Cycle And Overheating

    100% Duty Cycle At 450 Amperes 60% Duty Cycle At 580 Amperes 6 Minutes Welding 4 Minutes Resting Continuous Welding Overheating Reduce Duty Cycle Minutes duty1 4/95 − SA-181 560 / 250 541-A TM-257 220 Page 8 XMT 450 CC/CV...

  • Page 13: Volt-Ampere Curves

    Curves of other set- tings fall between curves shown. CC Mode STICK STICK REMOTE SCRATCH ARC CONTROL (DIG) 100% AMPERAGE CV MODE AMPERAGE 252 918-A / 252 919-A TM-257 220 Page 9 XMT 450 CC/CV...

  • Page 14: Section 4 − Installation

    Use cart or similar device to move unit. Line Disconnect Device Locate unit near correct input power supply. 18 in. (460 mm) Ref. ST-151 556 / 800 611 / Ref. 250 026-B Notes TM-257 220 Page 10 XMT 450 CC/CV...

  • Page 15: Weld Output Terminals And 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-K 2013−10 TM-257 220 Page 11...

  • Page 16: Connecting Weld Output Cables

    Current feedback; +1 volt DC per 100 amperes. AMPERAGE Voltage feedback; +1 volt DC per 10 arc volts. VOLTAGE Circuit common for 24 volt AC circuit. Chassis common. *The remaining sockets are not used. TM-257 220 Page 12 XMT 450 CC/CV...

  • Page 17: 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 overload. Press button to reset supplement- ary protector. Ref. 257 348-A Notes TM-257 220 Page 13 XMT 450 CC/CV...

  • Page 18: Optional Gas Valve Operation And Shielding Gas Connection

    The minimum post−flow time is 5 seconds. The maximum post− flow is 24 seconds (post flow set- tings are not adjustable by the end user). GAS OUT Ref. 252 021-A / 257 348-A TM-257 220 Page 14 XMT 450 CC/CV...

  • Page 19: Electrical Service Guide

    4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. Notes TM-257 220 Page 15 XMT 450 CC/CV...

  • Page 20: Connecting Input Power

    4-8. Connecting Input Power = GND/PE Earth Ground Tools Needed: 5/16 in. Input5 2013−04 / Ref. 803 766-C / 257 348-A TM-257 220 Page 16 XMT 450 CC/CV...
  • Page 21 Welding Power Source Line Terminals ures to put unit in service. Input5 2013−04 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. TM-257 220 Page 17 XMT 450 CC/CV...

  • Page 22: Section 5 − General Operation

    (See Sections 6-2 thru 8-3). played for approximately three seconds Mode Switch after the arc is broken. Remote 14 Receptacle Weld Output Terminal (−) Adjust Control Left Display Right Display Power Switch 10 Weld Output Terminal (+) TM-257 220 Page 18 XMT 450 CC/CV...

  • Page 23: Mode Switch Settings

    Amps % Panel Amps CAC-A SMAW Stick Electrode Hot Amps % Panel Amps** CAC-A V-Sense Feeder GMAW Electrode Hot Volts Volts *Requires an external pulsing device. **See Section 8-5 Alternate Configuration Functions Notes TM-257 220 Page 19 XMT 450 CC/CV...

  • Page 24: Section 6 − Gtaw Operation

    Turn off power before making con- nections. Connect desired remote control to Remote Negative (−) Weld Output Terminal 14 receptacle if required. Foot Control TIG Torch Gas In Connection (Optional) Positive (+) Weld Output Terminal Gas Cylinder Workpiece TM-257 220 Page 20 XMT 450 CC/CV...

  • Page 25: Scratch Start Tig Welding Mode - Gtaw Process

    For best results, gently scratch the tungsten electrode to the work to initi- ate an arc. To minimize arc flare at the end of the weld, pull back the electrode quickly to extinguish the arc. TM-257 220 Page 21 XMT 450 CC/CV...

  • Page 26: Lift-Arc Tig Welding Mode - Gtaw Process

    Touch tungsten electrode to at the end of the weld, pull back the Preset amperage is shown in the Right Dis- workpiece at weld start point. Slowly lift electrode quickly to extinguish the arc. TM-257 220 Page 22 XMT 450 CC/CV...

  • Page 27: Remote Scratch Start Tig Welding Mode - Gtaw Process

    For best results, gently scratch the tungsten electrode to the work to initi- ate an arc. To minimize arc flare at the end of the weld, pull back the electrode quickly to extinguish the arc. TM-257 220 Page 23 XMT 450 CC/CV...

  • Page 28: Section 7 − Gmaw/Fcaw Operation

    DCEP (reverse polarity) suitable for all Positive (+) Weld Output Terminal wires except self-shielded FCAW. The Gas Hose Negative (−) Weld Output Terminal majority of self-shielded FCAW wires Ground Cable to Workpiece Gas Cylinder require DCEN (straight polarity). TM-257 220 Page 24 XMT 450 CC/CV...

  • Page 29: Mig Welding Mode - Gmaw/Fcaw Process

    For self-shielding wires (FCAW), ad- For typical system connections refer to has a voltage control. This voltage con- Section 7-1. trol will override the Adjust Control of just Arc Control to FCAW setting. TM-257 220 Page 25 XMT 450 CC/CV...

  • Page 30: Typical Connection For Remote Control Feeder Gmaw-P Process

    Positive (+) Weld Output Terminal 10 Gas Cylinder cored wires are not pulsed. No pulse Negative (−) Weld Output Terminal Use of shielding gas is dependant on Wire program available for FCAW. Ground Cable to Workpiece Type. TM-257 220 Page 26 XMT 450 CC/CV...

  • Page 31: Pulsed Mig Welding Mode - Gmaw-P Process

    Rotate Mode Switch to PULSED MIG posi- formation. Left Display tion as shown. Right Display When Pulsed MIG mode is selected, Adjust Control Left and Right Display will show PPP PPP. Arc Control is not functional. TM-257 220 Page 27 XMT 450 CC/CV...

  • Page 32: Typical Connection For Voltage-Sensing Feeder Gmaw/Fcaw Process

    Negative (−) Weld Output Terminal Gas Hose wires require DCEN (straight polar- Ground Cable to Workpiece 10 Gas Cylinder ity). Workpiece Use of shielding gas is dependant on Wire Voltage Sensing Clamp Type. TM-257 220 Page 28 XMT 450 CC/CV...

  • Page 33: V-Sense Feeder Welding Mode - Gmaw/Fcaw Process

    The Left Display toggling momentarily For self-shielding wires (FCAW), ad- For typical system setup connections refer pauses while the preset voltage is ad- to Section 7-5. justed. just Arc Control to FCAW setting. TM-257 220 Page 29 XMT 450 CC/CV...

  • Page 34: Section 8 − Smaw/Cac-A Operation

    14 receptacle as required. nections. Electrode Holder Compressed Air LIne Electrode Holder (Carbon Arc) Positive (+) Weld Output Terminal Negative (−) Weld Output Terminal For CAC-A process connect carbon arc Remote 14 Receptacle Workpiece TM-257 220 Page 30 XMT 450 CC/CV...

  • Page 35: Remote Stick Welding Mode - Smaw/Cac-A Process

    For best results at the end of the weld, The preset amperage is shown in the Right pull back the electrode quickly to extin- Display with the Amps Indicator lit. guish the arc. TM-257 220 Page 31 XMT 450 CC/CV...

  • Page 36: Stick Welding Mode - Smaw/Cac-A Process

    This helps eliminate electrode sticking dur- ing arc initiation. For best results at the end of the weld, pull back the electrode quickly to extin- guish the arc. TM-257 220 Page 32 XMT 450 CC/CV...

  • Page 37: Optional Low Open Circuit Voltage (Ocv) Welding Modes

    When CC mode is active, a decimal point will be displayed in the amperage window. TM-257 220 Page 33 XMT 450 CC/CV...

  • Page 38: Section 9 − Theory Of Operation

    Secondary Fan Motor Fan Motor Ribbon Heat Sink Heat Sink Solenoid Cable Supplementary Protector Operator Interface Board Process Voltmeter Ammeter Selector Remote 14‐Pin Receptacle Voltage RC50 Weld Process Arc Control Amperage Control Adjust TM-257 220 Page 34 XMT 450 CC/CV...
  • Page 39 Current Stabilizer Transducer Negative (−) Positive (+) Weld Output Weld Output Terminal Terminal Work Electrode Weld Voltage Feedback Weld Voltage Feedback Weld Current Feedback Control Circuit Primary Circuit Weld Current Circuit ♦ Optional XMT 450 CC/CV TM-257 220 Page 35...
  • Page 40 PC1 Provides primary current feedback to invert- Provides weld output connection to the • Contains weld control process er control board PC1 from main transformer workpiece of the weld circuit. TM-257 220 Page 36 XMT 450 CC/CV...

  • Page 41: Section 10 − Troubleshooting

    Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit. See the Miller Extranet for service memos that may aid in the repair of this product. Measure voltage of input capacitors according to Section 10-2 and be sure voltage is near zero before touching any parts.

  • Page 42: Removing Case And Measuring Input Capacitor Voltage

    Proceed with job inside unit. Rein- stall right side panel when finished. 400 VAC input: + lead to lower terminal, − lead to upper terminal Ref. 256 682-A TM-257 220 Page 38 XMT 450 CC/CV...

  • Page 43: Input Rectifier Sr1

    E (−) B (AC Line 2) E (−) C (AC Line 3) If the input rectifier diodes are defective, check the three poles of the input contactor W1, the DMM should read OL. XMT 450 CC/CV TM-257 220 Page 39...

  • Page 44: Igbt Modules Pm1, Pm2

    PM1 and PM2 2. Check function of IBGT’s in PM1 and PM2 with IGBT tester (MILLER Part No. 043 553). Disconnect gate lead Plug 3 from receptacle RC3 on Inverter Control board PC1. Connect tester to module terminals and gate lead plug as follows: Module IGBT Tester Positive Lead −...

  • Page 45: Interconnect Board Pc2

    Re-install terminal screws after checking before continuing. 4. Check bus capacitors C3, C4, C5, and C6 for a short using the ohms position on the DMM. XMT 450 CC/CV TM-257 220 Page 41...

  • Page 46: Output Diodes

    D2 Anode (Bottom Terminal) D2 Cathode (Base) D3 Anode (Top Terminal) D3 Cathode (Base) D3 Anode (Bottom Terminal) D3 Cathode (Base) D4 Anode (Top Terminal) D4 Cathode (Base) D4 Anode (Bottom Terminal) D4 Cathode (Base) TM-257 220 Page 42 XMT 450 CC/CV...

  • Page 47: Input Contactor W1

    Disconnect lead at interconnect PC2 for proper measurement. Pre-power checks are now complete. Remove earth grounded wrist strap before performing any checks or procedures with power ap- plied to the machine. Ref. 255 761-A XMT 450 CC/CV TM-257 220 Page 43...

  • Page 48: Troubleshooting Table

    See Section 10-11 or 10-13 for test points and values and Section 13 for parts location. Use MILLER Testing Booklet (Part No. 150 853) 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;...

  • Page 49: Help Codes

    Thermistor resistance will have dropped to <130 ohms (shorted) or will have risen to >1.2M ohms (open). Wiring malfunction. Check condition of wiring. Front panel display board Replace PC3. PC3 malfunction. XMT 450 CC/CV TM-257 220 Page 45...
  • Page 50 −−−−−−− function. within allotted time. LED3 is lit on In- verter Control Board PC1. Tank capacitors C1 and C2 Check the indicated value of (too high of a value). C1 and C2. TM-257 220 Page 46 XMT 450 CC/CV...
  • Page 51 With unit on, wait 15 minutes limit. Output stops and cooling high of a welding current for for unit to cool. Reduce am- fan runs. too long. perage, voltage, wire feed speed, or duty cycle before welding. XMT 450 CC/CV TM-257 220 Page 47...

  • Page 52: Troubleshooting Circuit Diagram For Welding Power Source (All Models) (Use With Section 10-12)

    Always check unit before applying power (see Section 10-1). 10-11. Troubleshooting Circuit Diagram For Welding Power Source (All Models) (Use With Section 10-12) V4 V5 R11, V7 TM-257 220 Page 48 XMT 450 CC/CV...
  • Page 53 Always check unit before applying power (see Section 10-1). Test Equipment Needed: 256 909-A XMT 450 CC/CV TM-257 220 Page 49...

  • Page 54: Readings For Troubleshooting Circuit Diagram (All Models) (Use With Section 10-11)

    +14 VDC in Stick and Scratch Start TIG modes when low open circuit voltage mode is enabled. +24 volts DC when gas is flowing. (RC6-6 reference) TM-257 220 Page 50 XMT 450 CC/CV...
  • Page 55 Always check unit before applying power (see Section 10-1). Notes XMT 450 CC/CV TM-257 220 Page 51...

  • Page 56: Inverter Control Board Pc1 Testing Information (Use With Section 10-14)

    Be sure plugs are secure before test- ing. See Section 10-14 for values during testing. Inverter Control Board PC1 No testing required for remaining plugs and receptacles. Test Equipment Needed: 250 818-C / 255 763-A TM-257 220 Page 52 XMT 450 CC/CV...

  • Page 57: Inverter Control Boards Pc1 Test Point Values

    Input capacitor feedback; +282 volts DC with respect to RC4-4 (top+) Not used Input Input capacitor feedback; +282 volts DC with respect to RC4-6 (bottom+) Input Input capacitor feedback; Reference for pin RC4-1 (top-) Not used XMT 450 CC/CV TM-257 220 Page 53...

  • Page 58: Inverter Control Board Pc1 Diagnostic Leds

    Indicates input bus capacitor voltage imbalance HELP 6 (See Section Normal LED 3 10-10 ON−Red Indicates primary circuit control malfunction HELP 6 (See Section Normal LED 4 10-10 ON−Red Indicates primary current detect malfunction HELP 6 (See Section TM-257 220 Page 54 XMT 450 CC/CV...
  • Page 59 Always check unit before applying power (see Section 10-1). Notes XMT 450 CC/CV TM-257 220 Page 55...

  • Page 60: Interconnect Board Pc2 Testing Information (Use With Section 10-17)

    Be sure plugs are secure before testing. See Section 10-17 for specific values during testing. Interconnect Board PC2 No testing required for remain- ing plugs and receptacles. Test Equipment Needed: 255 761-A / 233 080-D TM-257 220 Page 56 XMT 450 CC/CV...

  • Page 61: Interconnect Board Pc2 Test Point Values

    Not used Line voltage with respect to pin RC9-10 Line voltage with respect to pin RC9-10 Line voltage with respect to pin RC9-6 or RC9-8 No testing required for remaining plugs and receptacles. XMT 450 CC/CV TM-257 220 Page 57...

  • Page 62: Front Panel/Display Board Pc3 Testing Information (Use With Section 10-19)

    Be sure plugs are secure before ap- plying power. See Section 10-19 for specific values during testing. Front Panel/Display Board No testing required for remain- ing plugs and receptacles. Test Equipment Needed: 243 575-B / 255 763-A TM-257 220 Page 58 XMT 450 CC/CV...

  • Page 63: Front Panel/Display Board Pc3 Test Point Values

    −24 volts DC, unregulated DC voltage with respect to GND, power feed to front panel pcb Input Negative weld output terminal; used for output voltage feedback Not Used Input Positive weld output terminal; used for output voltage feedback XMT 450 CC/CV TM-257 220 Page 59...

  • Page 64: Checking Unit Output After Servicing

    Weld Output Terminals Check open-circuit voltage be- tween terminals according to Sec- tion 10-11 (voltage V-15) If correct voltage is not present, repeat troubleshooting procedures. Reinstall cover and side panels if removed. 252 018-A TM-257 220 Page 60 XMT 450 CC/CV...

  • Page 65: Enabling Low Open Circuit Voltage Welding Modes (Optional)

    15 volts DC. Front Panel And Display Board PC3 Remove wrapper. Place switch position 1 in the Closed position by pressing actua- tor toward board. Reinstall wrapper. 256 682-A / 243 575-B XMT 450 CC/CV TM-257 220 Page 61...

  • Page 66: Checking Bus Voltage Imbalance

    Right Side Panel Interconnect Board PC2 Voltmeter Remove right side panel. Connect unit to a 400 VAC line. Connect a Miller Load Bank to the weld terminals, set load bank switches to off. Connect two DVM’s as shown. Select MIG process.

  • Page 67: Section 11 − Maintenance

    Blow Out Inside 11-2. Blowing Out Inside Of Unit Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown. 250 025-A XMT 450 CC/CV TM-257 220 Page 63...
  • Page 68 Notes TM-257 220 Page 64 XMT 450 CC/CV...

  • Page 69: Section 12 − Electrical Diagram

    The following is a list of all diagrams for models covered by this manual. Model Serial Or Style Number Circuit Diagram Wiring Diagram XMT 450 CC/CV 400 Volt MC100104A and following 256 909-A 256 916-C 256 497-B ♦♦ Circuit Board PC1 MC100104A and following 202 847-C ♦♦...
  • Page 70 Figure 12-1. Circuit Diagram For 400 Volt Models Effective With MC100104A And Following TM-257 220 Page 66 XMT 450 CC/CV...
  • Page 71 256 909-A XMT 450 CC/CV TM-257 220 Page 67...
  • Page 72 Figure 12-2. MC100104A Wiring Diagram for XMT 450 CC/CV (400 Volt) Eff. w/ And Following (1 of 2) TM-257 220 Page 68 XMT 450 CC/CV...
  • Page 73 256 916-C XMT 450 CC/CV TM-257 220 Page 69...
  • Page 74 Figure 12-3. Wiring Diagram for XMT 450 CC/CV (400 Volt) Eff. w/MC100104A And Following (2 of 2) TM-257 220 Page 70 XMT 450 CC/CV...
  • Page 75 256 916-C XMT 450 CC/CV TM-257 220 Page 71...
  • Page 76 Notes TM-257 220 Page 72 XMT 450 CC/CV...
  • Page 77 TM-257 220B 2015−03 Eff w/Serial Number MC100104A Processes Multiprocess Welding Description Arc Welding Power Source XMT 450 CC/CV (400 Volt Model) CE Eff w/MC100104A And Following For OM-257 220 Revisions A Thru H Visit our website at www.MillerWelds.com...

  • Page 78: Section 13 − Parts List

    SECTION 13 − PARTS LIST Hardware is common and not available unless listed. Figure 13-1. Parts Assembly XMT 450 CC/CV TM-257 220 Page 74...
  • Page 79 257 223-D XMT 450 CC/CV TM-257 220 Page 75...
  • Page 80 251 151 Label, XMT 450 CC/CV ......... .
  • Page 81 ........... . XMT 450 CC/CV...
  • Page 82 +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. XMT 450 CC/CV TM-257 220 Page 78...
  • Page 83 Notes...
  • Page 84 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 2015 Miller Electric Mfg. Co. 2015−01...

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