Miller XMT 450 CC/CV Owner's Manual
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Miller XMT 450 CC/CV Owner's Manual

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OM-251387S
2020−04
Processes
Multiprocess Welding
Description
Arc Welding Power Source
XMT 450 CC/CV
R
For product information,
File: MULTIPROCESS
Owner's Manual translations,
and more, visit
www.MillerWelds.com

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  • Page 1 OM-251387S 2020−04 Processes Multiprocess Welding Description Arc Welding Power Source XMT 450 CC/CV For product information, File: MULTIPROCESS 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 ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 8 − GMAW/FCAW OPERATION ............8-1.

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2020−02 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 Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

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

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

  • Page 8: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2020−02_fre 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 Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...

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

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...

  • Page 12: Proposition Californienne 65 Avertissements

    D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.

  • Page 13: 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. Safe26 2012−05 Always wear long sleeves and button your collar when servicing unit.

  • Page 14: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Amperage Positive Alternating Current (AC) Constant Voltage Voltage Primary Voltage Degree Of Protection Voltage Input Lift-Arc Trigger Hold Protective Earth Operation (GTAW) (Ground) Maximum Effective 1eff Supply Current Line Connection Voltage Sensing Three Phase Static Feeder Frequency Convert- er-Transformer-...

  • Page 15: Section 4 − Specifications

    4-5. 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 16: Dimensions And Weight

    4-7. Dimensions and Weight Hole Layout Dimensions 8-11/16 in. (221 mm) 11-3/8 in. (289 mm) 26.8 in. (681 mm) 15-3/4 in. (400 mm) 17.2 in. 22-7/16 in. (570 mm) (437 mm) 2-3/4 in. (70 mm) 3-3/8 in. (86 mm) Dia. 1/4-20 UNC 2B Thread 14.5 in.

  • Page 17: Duty Cycle And Overheating

    4-9. 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 18: Volt-Ampere Curves

    4-10. 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 252918-A / 252919-A OM-251387 Page 14...

  • Page 19: 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 20: Selecting Input Voltage (230/460 Volt Models Only)

    5-2. 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 21: Selecting Cable Sizes

    5-3. 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 22: Connecting Weld Output Cables

    5-5. Connecting Weld Output Cables Do not place anything between weld cable terminal and copper bar. Tools Needed: 3/4 in. (19 mm) Incorrect Installation 803778-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 23: Supplementary Protector

    5-7. Supplementary Protector Supplementary Protector CB2 CB2 protects 24 volts AC portion of Remote receptacle from overload. Press button to reset supplement- ary protector. 252020-B Notes OM-251387 Page 19...

  • Page 24: 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 25: Electrical Service Guide

    5-9. Electrical Service Guide Elec Serv 2020-02 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 26: Connecting Input Power

    5-10. Connecting Input Power = GND/PE Earth Ground L1 L2 Tools Needed: 5/16 in. Input5 2013−04 / Ref. 803766-C / 218005-A OM-251387 Page 22...
  • Page 27 5-10. Connecting Input Power (Continued) Supplied Cord) Connect input conductors L1, L2, and L3 to Turn Off welding power source, and welding power source line terminals. check voltage on input capacitors Select size and length of conductors using according to Section 10-3 before Section 5-3.

  • Page 28: Section 6 − General Operation

    SECTION 6 − GENERAL OPERATION 6-1. Front Panel 252022-A / 251142-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 (See Sections 7-2 thru 9-3).

  • 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 252920-C 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 251142-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 251142-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 251142-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 shown.

  • Page 34: Section 8 − Gmaw/Fcaw Operation

    SECTION 8 − GMAW/FCAW OPERATION 8-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process 252921-C 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 251142-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 252836-C 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 PP.P PPP 251142-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 252924-C 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 251142-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 252926-C 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. Electrode Holder Compressed Air LIne Electrode Holder...

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

    9-2. CC Welding Mode - SMAW/CAC-A Process 251142-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. ting from 0 to 100.

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

    9-3. Stick Welding Mode - SMAW/CAC-A Process 8 4.5 251142-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 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 44: Section 10 − Maintenance & Troubleshooting

    SECTION 10 − MAINTENANCE & TROUBLESHOOTING 10-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean Δ = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months nl Labels...

  • Page 45: Measuring/Discharging Input Capacitor Voltage Before Working On Unit

    10-3. Measuring/Discharging Input Capacitor Voltage Before Working On Unit 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 5 watt resistor...

  • Page 46: 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 47: Troubleshooting

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

  • Page 48: Section 11 − Electrical Diagram

    SECTION 11 − ELECTRICAL DIAGRAM Figure 11-1. Circuit Diagram OM-251387 Page 44...
  • Page 49 263 254-B OM-251387 Page 45...

  • Page 50: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. Figure 12-1. Parts Assembly OM-251387 Page 46...
  • Page 51 252023-E OM-251387 Page 47...
  • Page 52 Item Dia. Part Description Quantity Mkgs. Figure 12-1. Parts Assembly ....249804 Panel, Side Rh W/Nut Insert (Includes) ......
  • Page 53 Item Dia. Part Description Quantity Mkgs. Figure 12-1. Parts Assembly (Continued) ....219844 Label, Warning Electric Shock/Exploding Parts−Wdles ....
  • Page 54 Notes...
  • Page 55 Effective January 1, 2020 (Equipment with a serial number preface of NA or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions Supplied Air Respirator (SAR) Boxes and Panels below, Miller Electric Mfg.
  • 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 2020 Miller Electric Mfg. LLC 2020−01...

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