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

Miller Electric XMT 456 CC Owner's Manual

Multiprocess welding
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www.MillerWelds.com
Invision 456P And
XMT 456 CC/CV
R
(400 Volt Models)
OM-203 034N
2007−10
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:
R
File: MIG (GMAW)

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  • Page 1 Visit our website at www.MillerWelds.com Invision 456P And XMT 456 CC/CV (400 Volt Models) OM-203 034N 2007−10 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:...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Manufacturer: Miller Electric Mg. Co. 1635 W. Spencer St. Appleton, WI 54914 USA Phone: (920) 734-9821 European Contact Signature: XMT 456 CC/CV...

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

    DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment.
  • Page 6 OM-203 034 Page 2 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards. 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 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 l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

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

    ACCUMULATIONS risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux.

  • Page 12: Proposition Californienne 65 Avertissements

    LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures.

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
  • Page 14 OM-203 034 Page 10...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Manufacturer’s Warning Label Definitions S-179 310 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 16 = <60 OM-203 034 Page 12 > 60 s S-179 309-A 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.

  • Page 17: Symbols And Definitions

    3-2. Symbols And Definitions Amperage Output Direct Current (DC) Constant Current Arc Force Rated No Load Voltage (Average) Hertz Pulsed Rated Maximum 1max 1eff Supply Current 3-3. WEEE Label Panel Circuit Breaker Gas Tungsten Arc Welding Positive Constant Voltage Shielded Metal Arc Welding (SMAW) Primary Voltage Degree Of...

  • Page 18: Manufacturer's Rating Labels

    3-4. Manufacturer’s Rating Labels CV Model CC/CV Model 217 204-C / 223 527-B OM-203 034 Page 14...

  • Page 19: Section 4 − Installation

    SECTION 4 − INSTALLATION This manual contains information on CC and CC/CV units. Differences between models are noted throughout this manual. 4-1. Specifications Input Rated Welding Amperage Power Power Output Output Range Range 450 A @ 38 Volts DC, Three 100% Duty Cycle;...

  • Page 20: Volt-Ampere Curves

    4-3. Volt-Ampere Curves 4-4. Dimensions And Weight Hole Layout Dimensions 14-21/64 in (363.9 mm) 20-3/4 in (527.1 mm) 23-27/64 in (594.9 mm) 24-31/32 in (634.2 mm) 12-3/8 in (314.3 mm) 9/32 in (7.1 mm) Dia. Weight 118 lb (53.5 kg) OM-203 034 Page 16 CV Modes CC Modes...

  • Page 21: Selecting A Location

    4-5. Selecting A Location Movement Location 18 in (460 mm) 4-6. Connecting To Weld Terminals Tools Needed: Tipping 18 in (460 mm) Do not move or operate unit where it could tip. Lifting Forks Use lifting forks to move unit. Extend forks beyond opposite side of unit.

  • Page 22: Weld Output Terminals And Selecting Cable Sizes

    4-7. Weld Output Terminals And Selecting Cable Sizes 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. Be sure this welding machine is installed and grounded according to this manual.

  • Page 23: Connecting Weld Output Cables

    4-8. Connecting Weld Output Cables Tools Needed: 3/4 in (19 mm) Turn off power before connecting to weld output terminals. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your ma- chine. 4-9. Remote 14 Receptacle Information C L N *The remaining sockets are not used.

  • Page 24: 115 Volts Ac Duplex Receptacle

    4-10. 115 Volts AC Duplex Receptacle 4-11. Electrical Service Guide 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 25: Connecting Input Power

    4-12. Connecting Input Power Tools Needed: 5/16 in Turn Off welding power source, and check voltage on input capacitors according to Section 6-3 before pro- ceeding. Check input voltage available at site. Remove left side panel. =GND/PE Always connect grounding conductor first.

  • Page 26: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Front Panel Controls For CV Only Models Power On/Off Switch The fan motor is thermostatically controlled and only runs when cooling is needed. 5-2. Mode And Voltage Control For CV Only Models OM-203 034 Page 22 Voltmeter (see Section 5-3) Ammeter (see Section 5-3) Voltage Adjustment Control...

  • 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 Preset Volts Pulsed Pulse Display 5-4. Front Panel Controls For CC/CV Models Power Switch The fan motor is thermostatically controlled and only runs when cooling is needed.

  • 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 Panel Control (GTAW) Lift-Arc Trigger Hold TIG (GTAW) TIG (GTAW) MIG (GMAW) Pulsed MIG (GMAW-P) Voltage-Sensing Wirefeeder Remote Control SMAW...

  • 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 Scratch Start TIG (GTAW) Lift-Arc Trigger...

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

    5-7. Lift-Arc TIG Procedure For CC/CV Models “Touch” Do NOT Strike Like A Match! OM-203 034 Page 26 1 − 2 Seconds 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.

  • Page 31: Section 6 − Maintenance & Troubleshooting

    SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Replace Damaged Or Unreadable Labels 6-2. Blowing Out Inside Of Unit Disconnect power before maintaining. 3 Months Repair Or Replace Cracked Cables Clean Tighten Weld Terminals 6 Months Blow Out Inside Maintain more often during severe conditions.

  • Page 32: Removing Case And Measuring Input Capacitor Voltage

    6-3. Removing Case and Measuring Input Capacitor Voltage + lead to lower right terminal, − lead to upper right terminal Tools Needed: 5/16 in OM-203 034 Page 28 Significant DC voltage can remain on capac- itors after unit is Off. Always check the volt- age as shown to be sure the input capacitors have discharged before working on unit.

  • Page 33: Voltmeter/Ammeter Help Displays

    6-4. Voltmeter/Ammeter Help Displays HE.L P−0 HE.L P−1 HE.L P−2 HE.L P−3 HE.L P−4 HE.L P−5 HE.L P−6 HE.L P−7 HE.L P−8 HE.L P−9 All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit.

  • Page 34: Troubleshooting

    6-5. Troubleshooting Trouble No weld output; unit completely inop- Place line disconnect switch in On position (see Section 4-12). erative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-12). Check for proper input power connections (see Section 4-12). No weld output;...
  • Page 35 Notes OM-203 034 Page 31...

  • 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 37 203 505-A OM-203 034 Page 33...
  • Page 38 Figure 7-2. Circuit Diagram For CC/CV Welding Power Source OM-203 034 Page 34...
  • Page 39 204 950−B OM-203 034 Page 35...

  • Page 40: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. OM-203 034 Page 36 Figure 8-1. Complete Assembly 802 261-E...
  • Page 41 Item Dia. Part Mkgs....187 234 ..... . 195 585 .
  • Page 42 Item Dia. Part Mkgs....180 732 ..... . 179 848 .
  • Page 43 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.

  • Page 44: Owner's Record

    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. 2007 Miller Electric Mfg. Co. 2007−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

This manual is also suitable for:

Xmt 456cvInvision 456p

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