Miller XMT 425 CC/CV Owner's Manual
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Miller XMT 425 CC/CV Owner's Manual

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OM-234 781R
2014−01
Processes
Multiprocess Welding
Description
Arc Welding Power Source
R
XMT 425 CC/CV
Auto-Line
™
IEC
File: MULTIPROCESS
Visit our website at
www.MillerWelds.com

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  • Page 1 OM-234 781R 2014−01 Processes Multiprocess Welding Description Arc Welding Power Source XMT 425 CC/CV Auto-Line ™ 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 − SMAW/CAC-A 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

    DES PIECES DE METAL ou DES LES BOUTEILLES peuvent exploser 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- D Utiliser des pochettes et des boîtes antista- pements de radio−navigation et de com-...

  • 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-234 781 Page 10...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Manufacturer’s Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.
  • Page 16 Do not weld on drums or any closed containers. Safe16 2012−05 Do not remove or paint over (cover) the label. Safe20 2012−05 When power is applied failed parts can explode or cause other parts to explode. Safe26 2012−05 Flying pieces of parts can cause injury. Always wear a face shield when servicing unit. Safe27 2012−05 Always wear long sleeves and button your collar when servicing unit.

  • Page 17: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous 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 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2.

  • Page 19: Duty Cycle And Overheating

    C. Information On Electromagnetic Compatibility (EMC) This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low− voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con- ducted as well as radiated disturbances.

  • Page 20: Volt-Ampere Curves

    4-6. Volt-Ampere Curves Volt-ampere curves show minimum A. CC Mode and maximum voltage and amper- age output capabilities of welding power source. Curves of other set- tings fall between curves shown. SMAW GTAW SMAW GTAW CONTROL 100% AMPERAGE B. CV Mode 5 00 AMPERAGE 217 836-A / 217 837-B...

  • Page 21: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Selecting a Location Lifting Handles Movement Use handles to lift unit. Hand Cart Do not move or operate unit Use cart or similar device to move where it could tip. unit. Line Disconnect Device Locate unit near correct input power supply.

  • 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-K 2013−01 OM-234 781 Page 18...

  • Page 23: Remote 14 Receptacle Information

    5-3. Remote 14 Receptacle Information Socket* Socket Information 24 volts AC. Protected by supplementary protect- or CB2. 24 VOLTS AC Contact closure to A completes 24 volts AC contactor control circuit. 115 volts AC. Protected by supplementary pro- C L N 115 VOLTS AC tector CB1.

  • Page 24: Optional Gas Valve Operation And Shielding Gas Connection

    5-5. 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 GAS IN Fitting has 5/8-18...

  • Page 25: Electrical Service Guide

    5-6. Electrical Service Guide Elec Serv 2011−08 NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available.

  • Page 26: Connecting 3-Phase Input Power

    5-7. Connecting 3-Phase Input Power = GND/PE Earth Ground Tools Needed: Input2 2012−05 Ref. 802 136-A / Ref. 803 879-B OM-234 781 Page 22...
  • Page 27 5-7. Connecting 3-Phase Input Power (Continued) voltage available at site. This unit can be con- Input Conductors (L1, L2 And L3) Installation must meet all National and nected to any input power between 208 and Local Codes − have only qualified per- Disconnect Device Line Terminals 575 VAC without removing cover to relink the sons make this installation.

  • Page 28: Section 6 − General Operation

    SECTION 6 − GENERAL OPERATION 6-1. Front Panel Controls 803 692A /242 020A values after arc initiation and remains dis- set towards maximum, “wetness” (puddle Weld process operation sections de- played for approximately three seconds fluidity) increases. scribe functionality of the identified items after the arc is broken.

  • Page 29: Mode Switch Settings

    6-2. Mode Switch Settings Switch Position Process Output Control Panel Adjust Remote Adjust Scratch Start TIG GTAW Electrode Hot Amps % Panel Amps Lift-Arc TIG GTAW Electrode Hot Amps % Panel Amps GTAW Remote 14 Amps % Panel Amps GMAW Remote 14 Volts Volts...

  • Page 30: Section 7 − Gtaw Operation

    SECTION 7 − GTAW OPERATION 7-1. Typical Connection For GTAW Process 264 339-A Remote 14 Receptacle Gas Out Connection (Optional) Turn off power before making con- nections. Connect desired remote control to Remote Negative (−) Weld Output Terminal 14 receptacle if required. Foot Control TIG Torch Gas In Connection (Optional)

  • Page 31: Scratch Start Tig Welding Mode - Gtaw Process

    7-2. Scratch Start TIG Welding Mode - GTAW Process 8 4.5 242 020-A Setup Operation Weld terminals are energized at all times in Scratch Start TIG welding For typical system connections refer to The Adjust Control is used to set desired mode.

  • Page 32: Lift-Arc Tig Welding Mode - Gtaw Process

    7-3. Lift-Arc TIG Welding Mode - GTAW Process 1 3. 5 242 020-A 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 33: Tig Welding Mode - Gtaw Process

    7-4. TIG Welding Mode - GTAW Process 242 020-A Setup Operation Weld terminals energized through the remote control in TIG For typical system connections refer to The Adjust Control is used to set desired welding mode. Section 7-1. preset amperage. Rotate Mode Switch to TIG position as A remote control is required to turn on the Mode Switch...

  • Page 34: Section 8 − Gmaw/Fcaw Operation

    SECTION 8 − GMAW/FCAW OPERATION 8-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process 264 343-A Workpiece Use of shielding gas is dependant on Wire Turn off power before making Type. connections. Remote 14-Receptacle The connection diagram illustrates Wire Feeder DCEP (reverse polarity) suitable for all Positive (+) Weld Output Terminal wires except self-shielded FCAW.

  • Page 35: Mig Welding Mode - Gmaw/Fcaw Process

    8-2. MIG Welding Mode - GMAW/FCAW Process 2 5.0 242 020-A Rotate Mode Switch to MIG position as has a voltage control. This voltage con- Weld terminals energized shown. trol will override the Adjust Control of through the remote control in MIG preset voltage on the welding power welding mode.

  • Page 36: Typical Connection For Remote Control Feeder Gmaw-P Process

    8-3. Typical Connection For Remote Control Feeder GMAW-P Process 264 347-A Workpiece Type. Turn off power before making connections. The connection diagram illustrates Optima - External Pulsing Device DCEP (reverse polarity) suitable for all Wire Feeder wires except self-shielded FCAW. The Remote 14-Receptacle Gas Hose majority of self-shielded FCAW wires...

  • Page 37: Pulsed Mig Welding Mode - Gmaw-P Process

    8-4. Pulsed MIG Welding Mode - GMAW-P Process P P.P 242 020-A Adjust Control Left and Right Display will show PPP PPP. Weld terminals energized through the remote control in Setup Operation Pulsed MIG welding mode. For typical system connections refer to This unit requires an external pulsing Mode Switch Section 8-3.

  • Page 38: Typical Connection For Voltage-Sensing Feeder Gmaw/Fcaw Process

    8-5. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process 264 348-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 Ground Cable to Workpiece...

  • Page 39: V-Sense Feeder Welding Mode - Gmaw/Fcaw Process

    8-6. V-Sense Feeder Welding Mode - GMAW/FCAW Process 2 5.0 242 020-A to Section 8-5. Weld terminals are energized at all The Left Display toggling momentarily times in V-Sense Feeder welding pauses while the preset voltage is ad- Rotate Mode Switch to V-SENSE FEEDER mode.

  • Page 40: Section 9 − Smaw/Cac-A Operation

    SECTION 9 − SMAW/CAC-A OPERATION 9-1. Typical Connection For SMAW And CAC-A Process 264 349-A cutting torch to to positive weld output ter- Connect desired remote control to remote Turn off power before making con- minal. 14 receptacle as required. nections.

  • Page 41: Cc Welding Mode - Smaw/Cac-A Process

    9-2. CC Welding Mode - SMAW/CAC-A Process 242 020-A Operation Arc Control (Dig) Weld terminals energized The Adjust Control is used to set desired through the remote control in CC Rotate Arc Control to select desired dig set- preset amperage. welding mode.

  • Page 42: Stick Welding Mode - Smaw/Cac-A Process

    9-3. Stick Welding Mode - SMAW/CAC-A Process 8 4.5 242 020-A 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 43: Optional Low Open Circuit Voltage (Ocv) Welding Modes

    9-4. Optional Low Open Circuit Voltage (OCV) Welding Modes Low OCV Operation The unit can be optionally config- ured for low open circuit voltage (OCV) operation in Stick and Scratch Start TIG modes. When the unit is configured for low OCV op- eration only a low sensing voltage (approximately 15 VDC) is present between the electrode and the...

  • Page 44: Section 10 − Maintenance & Troubleshooting

    SECTION 10 − MAINTENANCE & TROUBLESHOOTING 10-1. Routine Maintenance Disconnect power Maintain more often during before maintaining. severe conditions. n = Check Z = Change ~ = Clean l = Replace Replace Damaged Replace Cracked Torch Body Unreadable n Z l Labels Repair Or Replace...

  • Page 45: Voltmeter/Ammeter Help Displays

    10-3. 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 1 Display HE.L P−1 Indicates a malfunction in the primary power cir- cuit. If this display is shown, contact a Factory Au- thorized Service Agent.

  • Page 46: Troubleshooting

    10-4. Troubleshooting Trouble Remedy No weld output; unit completely inop- Place line disconnect switch in On position (see Section 5-7). erative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-7). Check for proper input power connections (see Section 5-7). No weld output;...
  • Page 47 Notes OM-234 781 Page 43...

  • Page 48: Section 11 − Electrical Diagram

    SECTION 11 − ELECTRICAL DIAGRAM Figure 11-1. Circuit Diagram OM-234 781 Page 44...
  • Page 49 256 233-A OM-234 781 Page 45...

  • Page 50: Section 12 − Parts List

    SECTION 12 − PARTS LIST 803 850-H Figure 12.1. Parts Assembly OM-234 781 Page 46...
  • Page 51 Item Dia. Part Mkgs. Description Quantity Figure 12.1. Parts Assembly ....216 034 Wrapper (Includes Insulators and Safety Labels) ....
  • Page 52 Item Dia. Part Mkgs. Description Quantity Figure 12.1. Parts Assembly (Continued) ....234 126 Nut, Conduit 1.000 Npt Knurled ........
  • Page 53 Item Dia. Part Mkgs. Description Quantity Figure 12.1. Parts Assembly (Continued) ....212 070 Panel, Front Standard ......... . .
  • Page 54 Notes...
  • Page 55 Effective January 1, 2014 (Equipment with a serial number preface of ME 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 56 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 2014 Miller Electric Mfg. Co. 2014−01...

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