Miller XMT 450 VS Owner's Manual
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Miller XMT 450 VS Owner's Manual

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OM-262 148N
2015−08
Processes
Multiprocess Welding
Description
Arc Welding Power Source
R
XMT 450 VS
With ArcReach
™
File: MULTIPROCESS
Visit our website at
www.MillerWelds.com

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Summary of Contents for Miller XMT 450 VS

  • Page 1 OM-262 148N 2015−08 Processes Multiprocess Welding Description Arc Welding Power Source XMT 450 VS With ArcReach ™ File: MULTIPROCESS Visit our website at 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 9 − GMAW/FCAW OPERATION ............9-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2013−09 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 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 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 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 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 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2013−09 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 10 D Ne pas raccorder plus d’une électrode ou plus d’un câble de D Avoir recours à des écrans protecteurs ou à des rideaux pour masse à une même borne de sortie de soudage. Débrancher le protéger les autres contre les rayonnements les éblouissements câble pour le procédé...

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

    LES BOUTEILLES peuvent exploser DES PIECES DE METAL ou DES si elles sont endommagées. SALETES peuvent provoquer des blessures dans les yeux. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Le soudage, l’écaillement, le passage de la endommagée, elle peut exploser.
  • Page 12 LES CHARGES ÉLECTROSTATI- RAYONNEMENT HAUTE QUES peuvent endommager les cir- FRÉQUENCE (H.F.) risque cuits imprimés. provoquer des interférences. D Établir la connexion avec la barrette de terre D Le rayonnement haute fréquence (H.F.) peut avant de manipuler des cartes ou des pièces. provoquer des interférences avec les équi- pements de radio−navigation et de com- D Utiliser des pochettes et des boîtes antista-...

  • Page 13: Proposition Californienne 65 Avertissements

    2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres formations congénitales et, dans certains cas, des cancers.
  • Page 14 OM-262 148 Page 10...

  • Page 15: Section 3 − Definitions

    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 When power is applied failed parts can explode or cause other parts to explode. Safe89 2012−07 Notes OM-262 148 Page 11...

  • Page 16: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Amperage Output Gas Metal Arc Welding (GMAW) Alternating Current (AC) Conventional Voltage Direct Current Load Voltage (DC) Rated Welding Constant Current Current Suitable For Weld- Voltage Input Single Phase ing In An Environ- ment With In- creased Risk Of Protective Earth Electric Shock...

  • Page 17: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Features And Benefits LVCt Line Voltage Compensation is circuitry that keeps the power source output constant regardless of input power fluctuation. Wind Tunnel Technologyt circulates air over components that require cooling, not over electronic circuitry, which reduces contaminants and im- proves reliability in harsh welding environments.

  • Page 18: Environmental Specifications

    4-6. Environmental Specifications A. IP Rating IP Rating IP23 This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless sheltered. IP2X 2014−06 4-7. Duty Cycle and Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.

  • Page 19: Volt-Ampere Curves

    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) 100% AMPERAGE CV MODE AMPERAGE 252 918-A / 252 919-A OM-262 148 Page 15...

  • Page 20: Section 5 − Installation

    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 21: Equipment Setup

    5-3. Equipment Setup process is taking place the decimal wire feeder displays weld voltage at wire During ArcReach operation, preset weld points on the wire feeder voltage display feeder. voltage and wire feed speed are set at the will blink. When associated, the decimal While welding, due to voltage drops in wire feeder front panel.

  • Page 22: Selecting Input Voltage (230/460 Volt Models Only)

    5-4. Selecting Input Voltage (230/460 Volt Models Only) Turn Off welding power source, disconnect input power, and check voltage on input capacitors accord- ing to Section 10-3 before proceeding. Be sure to reinstall all four screws securing relinking board in place. Check input voltage available at site.

  • Page 23: 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-L 2015−02 5-6. Weld Output Terminals Turn off power before connecting to weld output terminals.

  • Page 24: Connecting Weld Output Cables

    5-7. 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 weld output terminals.

  • Page 25: Optional Gas Valve Operation And Shielding Gas Connection

    5-8. 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. Gas Hose Connection Fitting has 5/8-18 right-hand...

  • Page 26: Electrical Service Guide

    5-9. 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 27 Notes OM-262 148 Page 23...

  • Page 28: Connecting Input Power

    5-10. Connecting Input Power = GND/PE Earth Ground L1 L2 Tools Needed: 5/16 in. Input5 2013−04 / Ref. 803 766-C / 262 154-A OM-262 148 Page 24...
  • Page 29 5-10. Connecting Input Power (Continued) Select size and length of conductors using Input Conductors L1, L2, L3 Turn Off welding power source, and Section 5-5. Conductors must comply with check voltage on input capacitors Connect input conductors L1, L2, and L3 to national, state, and local electrical codes.

  • Page 30: Section 6 − General Operation

    SECTION 6 − GENERAL OPERATION 6-1. Front Panel 261 358-B / 262 158-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 played for approximately three seconds Mode Switch...

  • Page 31: Mode Switch Settings

    6-2. Mode Switch Settings Panel Adjust Switch Position Process Output Control Feeder Adjust (when not linked) FCAW NO GAS FCAW At Wire Feeder Volts Volts Lift-Arc TIG GTAW Electrode Hot Amps Scratch Start TIG GTAW Electrode Hot Amps SMAW Stick Electrode Hot Amps Amps...

  • Page 32: Section 7 − Gtaw Operation

    SECTION 7 − GTAW OPERATION 7-1. Typical Connection For GTAW Process 262 161-A Gas In Connection (Optional) Negative (−) Weld Output Terminal Turn off power before making con- nections. Gas Cylinder TIG Torch Positive (+) Weld Output Terminal Gas Out Connection (Optional) Workpiece OM-262 148 Page 28...

  • Page 33: Lift-Arc Tig Welding Mode - Gtaw Process

    7-2. Lift-Arc TIG Welding Mode - GTAW Process 261 358-B 1 − 2 “Touch” Seconds Do NOT Strike Like A Match! Setup Operation Weld terminals are energized at all times in Lift Arc TIG welding mode. For typical system connections refer to The Adjust Control is used to set desired Section 7-1.

  • Page 34: Scratch Start Tig Welding Mode - Gtaw Process

    7-3. Scratch Start TIG Welding Mode - GTAW Process 8 4.5 261 358−B Setup Operation Weld terminals are energized at all times in Scratch Start TIG welding The Adjust Control is used to set desired For typical system connections refer to mode.

  • Page 35: Section 8 − Smaw/Cac-A Operation

    SECTION 8 − SMAW/CAC-A OPERATION 8-1. Typical Connection For SMAW And CAC-A Process 262 165-A For CAC-A process connect carbon arc Positive (+) Weld Output Terminal Turn off power before making con- cutting torch to to positive weld output ter- nections.

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

    8-2. Stick Welding Mode - SMAW/CAC-A Process 261 358-B 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. Rotate Arc Control to select desired dig set- in the Right Display.

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

    8-3. 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 38: Section 9 − Gmaw/Fcaw Operation

    SECTION 9 − GMAW/FCAW OPERATION 9-1. Typical Connection For GMAW/FCAW Process 262 164-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 DCEP (reverse polarity) suitable for all...

  • Page 39: Mig Welding Mode - Mig/Fcaw With Gas Process

    9-2. MIG Welding Mode - MIG/FCAW With Gas Process 261 358-B Rotate Mode Switch to MIG/FCAW WITH has a voltage control. This voltage con- Weld terminals energized GAS position. trol will override the Adjust Control of through the remote control in MIG preset voltage on the welding power welding mode.

  • Page 40: Mig Welding Mode - Fcaw No Gas Process

    9-3. MIG Welding Mode - FCAW No Gas Process 261 358-B Rotate Mode Switch to FCAW NO GAS po- Arc Control (Inductance) Weld terminals are energized at all sition. times in FCAW welding mode. Rotate Arc Control to select desired induc- The Left Display toggles between open cir- tance setting from 0 to 100.

  • Page 41: Section 10 − Maintenance & Troubleshooting

    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 Repair Or Replace Cracked Cables And Cords Clean Tighten Weld...

  • Page 42: Removing Right Side Panel And Measuring Input Capacitor Voltage In 230/460 Volt Models

    10-3. Removing Right Side Panel and Measuring Input Capacitor Voltage In 230/460 Volt 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. Always check the voltage as shown to be sure 25 to 1000 ohm, the input capacitors have...

  • Page 43: Help Displays

    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. Help 1 Display HE.L Indicates a malfunction in the primary power circuit. If this display is shown, contact a Fac- tory Authorized Service Agent.

  • Page 44: Section 11 − Electrical Diagram

    SECTION 11 − ELECTRICAL DIAGRAM Figure 11-1. Circuit Diagram OM-262 148 Page 40...
  • Page 45 271 537-C OM-262 148 Page 41...

  • Page 46: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. Figure 12-1. Parts Assembly OM-262 148 Page 42...
  • Page 47 261 980-E OM-262 148 Page 43...
  • Page 48 Item Dia. Part Description Quantity Mkgs. Figure 12-1. Parts Assembly ....249804 Panel, Side Rh W/Nut Insert ........
  • Page 49 Item Dia. Part Description Quantity Mkgs. Figure 12-1. Parts Assembly (Continued) ... 251592 Circuit Card Assy, Control w/Program .......
  • Page 50 Notes...
  • Page 51 Effective January 1, 2015 (Equipment with a serial number preface of MF 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 52 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 2015 Miller Electric Mfg. Co. 2015−01...

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