Miller XMT 650 ArcReach 380/400V CE Owner's Manual
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Miller XMT 650 ArcReach 380/400V CE Owner's Manual

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OM-295216B
2024-06
Processes
Multiprocess Welding
Description
Arc Welding Power Source
XMT 650
ArcReach 380V/400V CE
OWNER'S MANUAL
For product information,
Owner's Manual translations,
and more, visit
www.MillerWelds.com

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Summary of Contents for Miller XMT 650 ArcReach 380/400V CE

  • Page 1 OM-295216B 2024-06 Processes Multiprocess Welding Description Arc Welding Power Source XMT 650 ArcReach 380V/400V CE OWNER’S MANUAL 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 Symbol Usage .
  • Page 4 TABLE OF CONTENTS 10-1 Typical Connection For SAW Process ................. 42 10-2 SAW—Subarc Remote Welding Mode .
  • Page 5 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. LLC, 1635 West 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), Commission Regulation(s) and Standard(s).
  • Page 6 DECLARATION OF CONFORMITY For United Kingdom (UKCA marked) products. MILLER Electric Mfg. LLC, 1635 West 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 Statutory Instrument(s) and Standard(s).
  • Page 7 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number XMT 650 ArcReach 380/400V CE 907844 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standards IEC 62822-1:2016, IEC 62822-2:2016 ☒ for occupational use ☐...

  • Page 9: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING 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 not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 10 HOT PARTS can burn. WELDING can cause fire or explosion. � Do not touch hot parts bare handed. � Allow cooling period before working on equipment. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. �...

  • Page 11: Additional Hazards For Installation, Operation, And Maintenance

    � Never weld on a pressurized cylinder—explosion will result. CYLINDERS can explode if � Use only correct compressed gas cylinders, regulators, hoses, damaged. and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition. pressure.

  • Page 12: California Proposition 65 Warnings

    � To reduce possible interference, keep weld cables as short as ARC WELDING can cause possible, close together, and down low, such as on the floor. interference. � Locate welding operation 100 meters from any sensitive electronic equipment. � Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, �...

  • Page 13: Section 2 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION 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 14 � Porter un harnais de sécurité si l’on doit travailler au-dessus du LES ACCUMULATIONS DE GAZ sol. risquent de provoquer des blessures � S’assurer que tous les panneaux et couvercles sont correctement ou même la mort. en place. � Fixer le câble de retour de façon à obtenir un bon contact métal- �...

  • Page 15: Symboles De Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    � Brancher le câble de masse sur la pièce le plus près possible de � Les porteurs d’implants médicaux doivent consulter leur médecin la zone de soudage pour éviter le transport du courant sur une lon- et le fabricant du dispositif avant de s’approcher de la zone où se gue distance par des chemins inconnus éventuels en provoquant déroule du soudage à...

  • Page 16: Proposition Californienne 65 Avertissements

    � Affûter l'électrode au tungstène uniquement à la meuleuse dotée LIRE LES INSTRUCTIONS. de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l'on porte l'équipement homologué de protection du vi- � Lire et appliquer les instructions sur les étiquettes sage, des mains et du corps.

  • Page 17: Informations Relatives Aux Cem

    Safety in Welding, Cutting, and Allied Processes, CSA Standard Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website: W117.2 from Canadian Standards Association. Website: www. csa- www.osha.gov. group.org. OSHA Important Note Regarding the ACGIH TLV, Policy Statement on the Uses of TLVs and BEIs.

  • Page 18: Section 3 - Definitions

    Warning! Watch Out! There are possible hazards as shown by the symbols. Some symbols are found only on CE products. facility. Contact your local recycling office or your local distributor for further information. Safe Safe Do not discard product (where applicable) with general waste. SECTION 3 –...
  • Page 19 Cutting sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Safe24 2017 Safe24 201 Safe24 201 Safe24 201 Do not grip material near cutting path. Safe15 2012 Safe18 201 Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye Use lift eye to lift unit and properly installed accessories only, not gas cylinders.
  • Page 20 Recycle or dispose of used coolant in an environmentally safe way. Recycle or dispose of used coolant in an environmentally safe way. Safe11 Safe119 2015 05 Hazardous voltage remains on input capacitors after power is turned Hazardous voltage remains on input capacitors after power is turned off.

  • Page 21: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Amperage Gas Output Output Alternating Current Foot Control (AC) Gas Metal Arc Voltage Direct Current (DC) Welding (GMAW) Conventional Load Constant Current Voltage Input Voltage Arc Force Panel Protective Earth Rated Welding Flux Cored Arc (Ground) Current Welding (FCAW)

  • Page 22: Section 4 - Specifications

    Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...

  • Page 23: Unit Specifications

    4-6. Unit Specifications � Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-8 and 5-9 for information on connecting input power. � This equipment will deliver rated output at an ambient air temperature up to 104°F (40°C). A.

  • Page 24: Dimensions And Weight

    4-7. Dimensions And Weight Hole Layout Dimensions 14–1/4 in. (362 mm) 30–1/4 in. (768 mm) 11/16 in. (17 mm) Weight 187 lb (84.8 kg) Ref. 294844 4-8. Environmental Specifications A. IP Rating IP Rating IP23 This equipment is designed for outdoor use. B.
  • Page 25 Some symbols are found only on CE products. D. EU Ecodesign Information Minimum Power Source Maximum Idle State Model Input Warning! Watch Out! There are possible hazards as shown by the symbols. Efficiency Power Consumption XMT 650 400V Three Phase 45.4 W Safe1 2012 Do not discard product (where applicable) with general waste.

  • Page 26: Duty Cycle And Overheating

    A complete Parts List is available at www.MillerWelds.com 3-4. Duty Cycle and Overheating 4-9. Duty Cycle And Overheating 31-5/8 in. (803 mm) 6-11/16 in. 406 mm) 269319-A Duty Cycle is percentage of 10 minutes that unit can weld rated load without ating overheating.

  • Page 27: Section 5 - Installation

    A complete Parts List is available at www.MillerWelds.com Writers: Remember to move unit dimension and weight and rating la- bel location information to the appropriate sections. SECTION 5 – INSTALLATION 5-1. Selecting A Location 1-3. Selecting A Location omplete Parts List is available at www.MillerWelds.com dimension and weight and rating la- Do not move or operate unit where ers: Remember to move unit dimension and weight and rating la-...

  • Page 28: Selecting Cable Sizes

    5-2. Selecting Cable Sizes* NOTICE – The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 29: Connecting Weld Output Cables

    5-4. Connecting Weld Output Cables output term1 2015 02 269322-A 2 Supplied Weld Output Terminal Nut shown, so that weld cable terminal is tight Turn off power before connecting to against copper bar. weld output terminals. 3 Supplied Weld Output Terminal Bolt Do not place anything between weld Failure to properly connect weld ca- cable terminal and copper bar.

  • Page 30: Supplementary Protector

    5-6. Supplementary Protector 1 15 Amp GFCI Receptacle See Section 5-7. 2 Supplementary Protector CB1 3 Supplementary Protector CB2 CB1 protects duplex receptacle. CB2 protects 24 volts AC portion of Remote 14 receptacle from overload. Press button reset supplementary protector. Ref.

  • Page 31: Gfci Receptacle Information, Resetting, And Testing

    5-7. GFCI Receptacle Information, Resetting, And Testing Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles auxiliary equipment. If unit does not button pops out, and the circuit opens to dis- If a GFCI fault occurs, turn off unit and dis- have GFCI receptacles, use GFCI- connect power to the faulty equipment.

  • Page 32: Electrical Service Guide

    5-8. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommen- dations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual branch circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.

  • Page 33: Connecting 3-Phase Input Power

    5-9. Connecting 3-Phase Input Power tools/ tools/ philips head wrench crescent wrench allen_set flathead philips head wrench crescent wrench tools/ Ref. 296058-A 3/8 in. 3/16 in. Select size and length of conductors using Reinstall side panel on welding power Significant DC voltage can remain allen_wrench allen_set flathead...

  • Page 34: Section 6 - General Operation

    SECTION 6 – GENERAL OPERATION 6-1. Front Panel Ref. 294843-A 4 Adjust Control 14 Arc Control Indicator For Wire Modes � Weld process operation sections de- 5 Power Switch 15 Amp Indicator scribe functionality of the identified items (See Sections 7-1 thru 10-1). 6 Arc Control Button 16 Arc Control Indicator For Stick Modes 7 Output On Indicator...

  • Page 35: Mode Switch Settings

    6-2. Mode Switch Settings Switch Position Process Output Control Panel Adjust Remote Adjust* GMAW/FCAW Gas Output On Volts No Remote Adjust FCAW-S No-Gas Output On Volts No Remote Adjust SMAW Stick Output On Amps % Panel Amps CAC-A Gouge Output On Amps % Panel Amps GTAW Lift-Arc TIG...

  • Page 36: Optional Voltage Reducing Device (Vrd) Mode

    6-4. Optional Voltage Reducing Device (VRD) Mode � VRD can only be turned ON and OFF with USB when DIP SW1 is in the UP position. See 6-5 for more information. � Enabling Voltage-Reducing Device (VRD) mode configures the XMT 650 to operate in VRD mode using low Open Circuit Voltage (Low-OCV).

  • Page 37: Activating Optional Voltage Reducing Device (Vrd) With Dip Switch

    6-5. Activating Optional Voltage Reducing Device (VRD) with DIP Switch Turn Off welding power source, and disconnect input power. Significant DC voltage can remain on capacitors after unit is Off. Wait 5 minutes after input power has been disconnected to allow ca- pacitors to discharge.

  • Page 38: Alternate Configuration Functions

    6-6. Alternate Configuration Functions The Function of the remote control and panel meters can be changed on this machine. To view or change the active configuration: � Place the process selection switch into SMAW (Stick) Output-on mode. � Quickly tap (press and release) the wire feeder gun trigger or remote output on–off switch 3 to 5 times within a few seconds to view the active configuration.

  • Page 39: Section 7 - Gtaw Operation

    SECTION 7 – GTAW OPERATION 7-1. Typical Connection For GTAW Process Connect desired remote control to Remote 6 Negative (-) Weld Output Terminal Turn power before making 14 receptacle if required. connections. 7 TIG Torch 1 Foot Control 4 Gas Cylinder 8 Workpiece 2 Positive (+) Weld Output Terminal 5 Gas Hose...

  • Page 40: Gtaw-Tig Remote Welding Mode

    7-2. GTAW—TIG Remote Welding Mode Rotate Mode switch to GTAW - TIG Remote Weld terminals energized � If the remote control has an amperage through the remote control in GTAW position as shown. adjustment, the adjustment will func- - TIG Remote welding mode. tion as a percentage of the preset am- The preset amperage is shown in the Right 1 Mode Switch...

  • Page 41: Gtaw - Lift-Arc Tig Output-On Welding Mode

    7-3. GTAW - Lift-Arc TIG Output-On Welding Mode 12.0 Ref 295174-A “Touch” Seconds Do NOT Strike Like A Match! Weld terminals are energized at all The open-circuit voltage is shown in the Left � If an ArcReach device is used for am- display with the Volt indicator lit.

  • Page 42: Section 8 - Gmaw/Fcaw Operation

    SECTION 8 – GMAW/FCAW OPERATION 8-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process Ref. 294846-A 6 Gun Turn power before making � The connection diagram illustrates connections. 7 Wire Feeder DCEP (reverse polarity) suitable for all 1 Remote 14-Receptacle wires except self-shielded FCAW.

  • Page 43: Gmaw/Fcaw-Remote Welding Mode

    8-2. GMAW/FCAW—Remote Welding Mode 25.0 Ref. 295174 Operation Arc Control Weld terminals energized through remote control While the Volts indicator is lit under the Left Pressing the Arc Control button allows ad- GMAW/FCAW Remote welding display, the Adjust control is used to set the justment of Arc Control settings.

  • Page 44: Typical Connection For Voltage-Sensing Feeder Gmaw/Fcaw Process

    8-3. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process Ref. 294847-A 6 Gun Use of shielding gas is dependant on Wire Turn power before making Type. connections. 7 Gun Trigger Receptacle � 1 Positive (+) Weld Output Terminal The connection diagram illustrates 8 Wire Feeder DCEP (reverse polarity) suitable for all 2 Negative (-) Weld Output Terminal...

  • Page 45: Gmaw/Fcaw - (Gas) Or Fcaw-S (No Gas) Output-On Welding Modes

    8-4. GMAW/FCAW - (Gas) Or FCAW-S (No Gas) Output-On Welding Modes 25.0 Ref. 295174 Pressing the Arc Control button allows ad- Weld terminals are energized at all � If associated to an ArcReach feeder times in GMAW/FCAW (Gas) and justment of Arc Control settings. with Cable Length Compensation the FCAW-S (No Gas) Output On weld- voltage display on the power source...

  • Page 46: Section 9 - Smaw/Cac-A Operation

    SECTION 9 – SMAW/CAC-A OPERATION 9-1. Typical Connection For SMAW And CAC-A Process If a wire feeder is plugged into the remote, it may require a configuration change to achieve desired functionality. See Section 6-6. 294848-A 3 Positive (+) Weld Output Terminal 6 Negative (-) Weld Output Terminal Turn power...

  • Page 47: Smaw-Stick Remote Welding Mode

    9-2. SMAW—Stick Remote Welding Mode Ref. 295174-A Weld terminals energized Adaptive Hot Start automatically increases Pressing the Arc Control button allows ad- through the remote control in SMAW welding amperage at the start of a weld. justment of Arc Control. —Stick Remote welding mode.

  • Page 48: Smaw-Stick Output On Welding Mode

    9-3. SMAW—Stick Output On Welding Mode 82.0 Ref. 295174-A When the Amps indicator is lit under the Weld terminals are energized at all � See Section 9-1 for information regard- right display, the Adjust control is used to set times in SMAW - Stick Output-On ing alternate configurations.

  • Page 49: Cac-A-Gouge Output On Mode

    9-4. CAC-A—Gouge Output On Mode 82.0 Ref. 295174-A Weld terminals are energized at all Rotate Mode switch to CAC-A-Gouge Out- � If an ArcReach device is used for am- times in CAC-A - Gouge Output-On put On position as shown. perage adjustment, it will have full welding mode.

  • Page 50: Section 10 - Saw Operation

    SECTION 10 – SAW OPERATION 10-1. Typical Connection For SAW Process 294849-A Turn power before making 4 Welding Power Source connections. 5 Weld Cable 2 14-Pin Cable 1 14-Pin To SubArc Digital Converter 3 120 VAC Cable 6 Work Cable �...

  • Page 51: 10-2. Saw-Subarc Remote Welding Mode

    The Remote In Use 5 Remote In Use Indicator indicator will be lit. See SAW controller Own- When using Miller Electric HDC DX control- Setup er’s Manual for additional information. ler, select Dimension 652 or SubArc DC 650 for power source selection.

  • Page 52: Section 11 - Maintenance And Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 11 – MAINTENANCE AND TROUBLESHOOTING pliers needlenose knife steelbrush nutdriver SECTION 17 MAINTENANCE & TROUBLESHOOTING chippinghammer 11-1. Routine Maintenance A complete Parts List is available at www.MillerWelds.com 17-1. Routine Maintenance SECTION 17 MAINTENANCE &...

  • Page 53: 11-3. Fault Code Diagnostics

    11-3. Fault Code Diagnostics HELP TEMP Right Display Left Display Toggles between the identity and Displays a number to specify fault to aid in to indicate a fault. troubleshooting. HELP Unit Display Toggles Message Description HELP IN HELP 1 XX Indicates a malfunction in the primary power circuit.

  • Page 54: 11-4. Troubleshooting

    11-4. Troubleshooting Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 5-9). inoperative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-9). Check for proper input power connections (see Section 5-9). No weld output;...
  • Page 55 OM-295216 Page 47...

  • Page 56: Section 12 - Electrical Diagrams

    SECTION 12 – ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram OM-295216 Page 48...
  • Page 57 Ref 295214-A OM-295216 Page 49...
  • Page 58 Notes...
  • Page 59 Effective January 1, 2024 (Equipment with a serial number preface of NE or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. � Field Options (NOTE: Field options are cov-...
  • Page 60 Appleton, WI 54914 USA tact your distributor and/or equipment manu- facturer’s Transportation Department. International Headquarters–USA USA Phone: 920-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2024-06...

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