Miller XMT 456 CC Owner's Manual
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Miller XMT 456 CC Owner's Manual

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Invision 456P And
R
XMT 456 CC/CV
(400 Volt Models)
OM-203 034Y
2011−05
Processes
Invision 456P:
MIG (GMAW) Welding
With Optional Equipment:
Pulsed MIG (GMAW-P)
XMT 456 CC/CV:
Multiprocess Welding
Description
Invision 456P:
XMT 456 CC/CV:
™
File: MIG (GMAW)
IEC

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Summary of Contents for Miller XMT 456 CC

  • Page 1 OM-203 034Y 2011−05 Processes Invision 456P: MIG (GMAW) Welding With Optional Equipment: Pulsed MIG (GMAW-P) XMT 456 CC/CV: Multiprocess Welding Description Invision 456P: XMT 456 CC/CV: ™ Invision 456P And XMT 456 CC/CV (400 Volt Models) File: MIG (GMAW) Visit our website at...
  • 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 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−01 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 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 oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

  • Page 7: 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 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz D Fermer l’alimentation du gaz comprimé en cas sous haute pression. Si une bouteille est endommagée, elle peut exploser.

  • Page 12: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 14 OM-203 034 Page 10...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Manufacturer’s Warning Label Definitions Warning! Watch Out! There are possible Breathing welding fumes can be 3.3 Do not weld on drums or any closed hazards as shown by the symbols. hazardous to your health. containers. 2.1 Keep your head out of the fumes.
  • Page 16 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 not touch fully charged capacitors.

  • Page 17: Symbols And Definitions

    3-2. Symbols And Definitions Alternating Amperage Panel Voltage Current (AC) Output Circuit Breaker Remote Gas Tungsten Arc Negative Voltage Input Welding Direct Current Protective Earth Positive Inductance (DC) (Ground) Constant Current Constant Voltage Foot Control Line Connection Three Phase Static Frequency Con- Shielded Metal Arc Gas Metal Arc...

  • Page 18: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

  • Page 19: Duty Cycle And Overheating

    4-4. 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. Reduce amperage or duty cycle before welding.

  • Page 20: Volt-Ampere Curves

    4-5. Volt-Ampere Curves Volt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of CV Modes unit. Curves of other settings fall be- tween curves shown. CC Modes va_curve1 4/95 − SA-181 561 / SA-181 562 4-6. Dimensions and Weight Hole Layout Dimensions 14-21/64 in.

  • Page 21: Selecting A Location

    4-7. Selecting A Location Movement Tipping Do not move or operate unit where it could tip. Lifting Forks Location Use lifting forks to move unit. Extend forks beyond opposite side of unit. Lifting Handles Use handles to lift unit. Hand Cart Use cart or similar device to move unit.

  • Page 22: 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-G 2009−08 OM-203 034 Page 18...

  • Page 23: Connecting Weld Output Cables

    4-10. Connecting Weld Output Cables Tools Needed: 3/4 in. (19 mm) 803 778-B cable terminal and copper bar. Make Weld Cable Terminal Turn off power before connecting to sure that the surfaces of the weld cable weld output terminals. Copper Bar terminal and copper bar are clean.

  • Page 24: 115 Volts Ac Duplex Receptacle

    4-12. 115 Volts AC Duplex Receptacle 115 VAC Receptacle Power is shared between duplex receptacle and Remote 14 recep- tacle (see Section 4-11). Supplementary Protector CB1 Supplementary Protector CB2 CB1 protects 115 volts AC portion of duplex receptacle and Remote 14 receptacle from overload.

  • Page 25: Connecting Input Power

    4-14. Connecting Input Power = GND/PE Earth Ground Tools Needed: 5/16 in. Input5 2011−03 803 245-C / Ref. 803 766-A / 218 005-A / 801 946 Select size and length of conductors using Reinstall side panel on welding power Turn Off welding power source, and Section 4-9.

  • Page 26: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Front Panel Controls For CV Only Models 184 761 Power On/Off Switch Voltmeter (see Section 5-3) Inductance Control The fan motor is thermostatically Inductance determines the “wetness” of the Ammeter (see Section 5-3) controlled and only runs when cooling is weld puddle.

  • Page 27: Meter Functions For Cv Only Models

    5-3. Meter Functions For CV Only Models The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle Meter Reading While Welding 24.5 24.5 Preset Volts Blank Actual Volts Actual Amps Pulsed 24.5...

  • Page 28: Meter Functions For Cc/Cv Models

    5-5. Meter Functions For CC/CV Models The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle 80.0 Panel Control (GTAW) Actual Volts (OCV) Preset Amps Lift-Arc Trigger Hold TIG (GTAW) Blank Preset Amps TIG (GTAW)

  • Page 29: Mode Switch Settings For Cc/Cv Models

    5-6. Mode Switch Settings For CC/CV Models The SMAW modes provide the Adaptive Hot Start™ feature, which automatically increases the output amperage at the start of a weld should the start require it. This eliminates electrode sticking at arc start. Mode Output Control Select:...

  • Page 30: Lift-Arc Tig Procedure For Cc/Cv Models

    5-7. Lift-Arc TIG Procedure For CC/CV Models With Mode switch in the Lift-Arc TIG position, start an arc as follows: TIG Electrode Workpiece Touch tungsten electrode to work- piece at weld start point, hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. An arc will form when electrode is lifted.

  • Page 31: Section 6 − Maintenance & Troubleshooting

    SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. 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 Repair Or Replace Cracked Cables And Cords Clean Tighten...

  • Page 32: Removing Case And Measuring Input Capacitor Voltage

    6-3. Removing Case and Measuring Input Capacitor Voltage Turn Off welding power source, and lockout/tagout input power before pro- ceeding. Significant DC voltage can Typical Bleeder Resistor remain on capacitors after unit is Off. Always check the 25 to 1000 ohm, voltage as shown to be sure 5 watt resistor the input capacitors have...

  • Page 33: Voltmeter/Ammeter Help Displays

    6-4. Voltmeter/Ammeter Help Displays All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Help 0 Display HE.L P−0 Indicates a shorted thermistor RT2 on the left side of the unit. If this dis- play is shown, contact a Factory Au- thorized Service Agent.

  • Page 34: Voltmeter/Ammeter Help Displays (Continued)

    6-5. Voltmeter/Ammeter Help Displays (Continued) All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Help 5 Display HE.L P−5 Indicates the right side of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 4-4).

  • Page 35: Troubleshooting

    6-6. Troubleshooting Trouble Remedy No weld output; unit completely inop- Place line disconnect switch in On position (see Section 4-14). erative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-14). Check for proper input power connections (see Section 4-14). No weld output;...

  • Page 36: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram For CV Only Welding Power Source OM-203 034 Page 32...
  • Page 37 239 524-B OM-203 034 Page 33...
  • Page 38 Figure 7-2. Circuit Diagram For CC/CV Welding Power Source OM-203 034 Page 34...
  • Page 39 239 526-B OM-203 034 Page 35...

  • Page 40: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. Ref. 802 261-G Figure 8-1. Complete Assembly OM-203 034 Page 36...
  • Page 41 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Complete Assembly ....187 234 . . . Cover, Top ........... .
  • Page 42 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Complete Assembly (Continued) ....186 621 . . . Boot, Generic Output Stud ........
  • Page 43 Effective January 1, 2011 (Equipment with a serial number preface of MB or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
  • Page 44 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 2011 Miller Electric Mfg. Co. 2011−01...

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