Miller XMT 400 CC/CV Owner's Manual
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Miller XMT 400 CC/CV Owner's Manual

Miller XMT 400 CC/CV Owner's Manual

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CC/CV DC Welding Power Source For GMAW, GMAW-P, FCAW, GTAW, GTAW-P And SMAW Welding
Rated
Voltage
Welding
Range In
Output
CV Mode
60% Duty
Cycle: 400 A
@ 36 VDC
10-36
100% Duty
Cycle: 300 A
@ 32 VDC
* While idling
cover_om 4/95 – ST-146 127-C
OWNER'S
MANUAL
XMT 400 CC/CV -
Maximum
Amperage
Open-
Range In
Circuit
CC Mode
Voltage DC
5-400
80
1996 MILLER Electric Mfg. Co.
March 1996
Effective With Serial No. KG049529
Amperes Input at Rated Load
Output, 50 Hz, Three-Phase
60% Duty Cycle
IP
380 V
415 V
Rating
32.6
30.4
23
(0.9)*
(0.9)*
Form: OM-139 426K
100% Duty
Cycle
380 V
415 V
KVA
23
21.6
21.7
(0.7)*
(0.6)*
(0.52)*
PRINTED IN USA
KW
16.6
(0.16)*

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Summary of Contents for Miller XMT 400 CC/CV

  • Page 1 @ 36 VDC 32.6 30.4 21.6 21.7 16.6 10-36 5-400 (0.9)* (0.9)* (0.7)* (0.6)* (0.52)* (0.16)* 100% Duty Cycle: 300 A @ 32 VDC * While idling  1996 MILLER Electric Mfg. Co. cover_om 4/95 – ST-146 127-C PRINTED IN USA...
  • Page 2 Declaration of Conformity For European Community (CE) Products Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA XMT 400 CC/CV Declares that the product: conforms to the following Directives and Standards: Directives Electromagnetic Compatibility Directives: 89/336/EEC, 92/31/EEC...

  • Page 4: Section 1 - Safety Precautions For Arc Welding

    SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING safety_som1 4/95 1-1. Symbol Usage Y Marks a special safety message. Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Means NOTE; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
  • Page 5 4. Never drape a welding torch over a gas cylinder. CYLINDERS can explode if damaged. 5. Never allow a welding electrode to touch any cylinder. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since 6.

  • Page 6: Principal Safety Standards

    OVERUSE can cause OVERHEATED SIGNIFICANT DC VOLTAGE exists after EQUIPMENT. removal of input power on inverters. 1. Allow cooling period. 1. Turn Off inverter, disconnect input power, and 2. Reduce current or reduce duty cycle before discharge input capacitors according starting to weld again.

  • Page 7: 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 from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand.
  • Page 8 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. V = 0 Always wait 60 seconds after power is turned off before working on unit.

  • Page 9: Manufacturer's Rating Labels For Ce Products

    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. Look at inside label, and properly position jumper links to match available input voltage.

  • Page 10: Symbols And Definitions

    2-3. Symbols And Definitions Gas Metal Arc Amperage Panel Voltage Welding (GMAW) Output Circuit Breaker Remote High Temperature Negative Voltage Input Direct Current Shielded Metal Arc Protective Earth Positive (DC) Welding (SMAW) (Ground) Constant Current Constant Voltage Wire Feed Line Connection Three Phase Static Frequency Con- Alternating...

  • Page 11: Selecting A Location

    SECTION 3 – INSTALLATION 3-1. Selecting A Location Lifting Handles Use handles to lift unit. Hand Cart Use cart or similar device to move Movement unit. Plate Label Rating Label Use rating label to determine input power needs. Label is on name- plate.

  • Page 12: Weld Output Receptacles And Selecting Cable Sizes

    3-3. Tipping Y Be careful when placing or moving unit over uneven surfaces. 3-4. Weld Output Receptacles 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.

  • Page 13: Remote 14 Receptacle Information

    3-5. Remote 14 Receptacle Information Socket* Socket Information 24 volts ac. Protected by circuit breaker CB2. 24 VOLTS AC 24 VOLTS AC C L N Contact closure to A completes 24 volts ac con- tactor control circuit. 115 volts ac. Protected by circuit breaker CB1. 115 VOLTS AC 115 VOLTS AC Contact closure to I completes 115 volts ac con-...

  • Page 14: Placing Jumper Links

    3-7. 115 Volt AC Receptacle 115 Volt AC Receptacle (Twistlock Shown) The receptacle on the rear of this unit supplies up to 5 amperes of 115 volt ac power. The receptacle is commonly used to power a cooling system. The receptacle may be twistlock or standard.

  • Page 15: Connecting Input Power

    3-10. Connecting Input Power Y Have only qualified persons make this installation. Input And Grounding Conductors Line Disconnect Device Select type and size overcurrent protection using Section 3-8. Y Special installation may be required where gasoline or GND/PE volatile liquids are present – Earth Ground see NEC Article 511 or CEC Section 20.

  • Page 16: Section 4 - Operation

    SECTION 4 – OPERATION 4-1. Front Panel Controls Ref. ST-179 379 Output (Contactor) Switch Use GMAW position for GMAW and FCAW. 10 Arc/Inductance Control Use SMAW position for SMAW, GMAW- Adjusts Arc Control with Mode switch in For weld output, place switch in On position. Pulsed, GTAW, and GTAW-Pulsed.

  • Page 17: Duty Cycle And Overheating

    4-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, over temperature light goes On and output stops. Let fan run for fifteen minutes. Reduce amperage or duty cycle before welding.

  • Page 18: Section 5 - Maintenance & Troubleshooting

    SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Repair Or Replace Replace Unreadable Cracked Labels Weld Cable Clean And Tighten Weld Connections Replace Cracked Parts 14-Pin Cord Gas Hose Torch Cable 6 Months Blow Out Or Vacuum Inside, During Heavy Service,...
  • Page 19 5-2. Removing Top Of Case And Measuring Input Capacitor Voltage Turn Off welding power source and disconnect input power. Y Significant DC voltage can remain on Outside Handle Screws capacitors after unit is Off. Always To loosen top, remove two outside check capacitors as shown to be sure handle screws from both handles they have discharged before working...

  • Page 20: Circuit Breakers And Fuses

    5-3. Circuit Breakers And Fuses Y Turn Off welding power source, disconnect input power, and check voltage on input capacitors according Section before proceeding. Circuit Breaker CB1 If CB1 opens, remote devices re- quiring 115 volts from Remote 14 receptacle RC2 or 115 volts ac re- ceptacle RC3 shut down.

  • Page 21: Troubleshooting

    5-4. Selecting Meter Hold Function On/Off With the hold function On, the meter display stays for 15 seconds after welding stops. With the hold func- tion Off, the meter display leaves when welding stops. Y Turn Off welding power source, disconnect input power, and check voltage on input capacitors according Section...
  • Page 22 Trouble Remedy Erratic or improper weld output. Clean and tighten all weld connections. Use proper size and type of weld cable (see Section 3-4). Check for proper input and output connections (see Sections 3-10 and 3-4). Replace electrode. Remote device completely inoperative. Check remote control connections (see Sections 3-5 and 3-6).

  • Page 23: Section 6 - Electrical Diagram

    SECTION 6 – ELECTRICAL DIAGRAM Figure 6-1. Circuit Diagram For Welding Power Source OM-139 426 Page 20...
  • Page 24 SD-179 918-A OM-139 426 Page 21...
  • Page 25 Fig 7-3 Fig 7-2...
  • Page 26 Item Dia. Part Mkgs. Description Quantity Figure 7-1. Main Assembly ....126 415 CLAMP, saddle ..........
  • Page 27 See Fig 7-1 Item 15 ST-159 262-A Figure 7-2. Panel, Front w/Components OM-139 426 Page 24...
  • Page 28 Item Dia. Part Mkgs. Description Quantity Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 29) ..C6,7 ..138 115 CAPACITOR, cer disc .1uf 500VDC .......
  • Page 29 14 15 ST-159 263-B Figure 7-3. Chassis, Mid OM-139 426 Page 26...
  • Page 30 Item Dia. Part Mkgs. Description Quantity Figure 7-3. Chassis, Mid (Fig 7-1 Item 21) ... . 156 313 TRANSDUCER, current 300A ........
  • Page 31 Item Dia. Part Mkgs. Description Quantity Figure 7-3. Chassis, Mid (Fig 7-1 Item 21) (Continued) ....166 251 IGBT, RH (consisting of) .........

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