Miller XMT 450 MPa Owner's Manual
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Miller XMT 450 MPa Owner's Manual

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OM-255083Q
2016−06
Processes
Multiprocess Welding
Description
Arc Welding Power Source
R
XMT 450 MPa
(400 Volt Model) CE
File: MULTIPROCESS
For product information,
Owner's Manual translations,
and more, visit
www.MillerWelds.com

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  • Page 1 OM-255083Q 2016−06 Processes Multiprocess Welding Description Arc Welding Power Source XMT 450 MPa (400 Volt Model) CE File: MULTIPROCESS 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 ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 8 − GMAW/GMAW-P/FCAW OPERATION ..........8-1.
  • Page 5 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 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) and Standard(s).
  • Page 6 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number XMT 450 CC/CV 400V W/AUX POWER (CE) 907525 XMT 450 MPA 400V (CE) 907468 INVISION 450 MPA 400V W/AUX POWER (CE) 907524 ALUMAPOWER 450 MPA 400V W/AUX POWER (CE) 907526...

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 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 8 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 9: 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 10: 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 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 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 12 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage.

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Tenir les bouteilles éloignées des circuits de soudage ou autres LE BRUIT peut endommager l’ouïe. circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. Le bruit des processus et des équipements peut affecter l’ouïe. D Une électrode de soudage ne doit jamais entrer en contact avec D Porter des protections approuvées pour les une bouteille.

  • Page 14: Proposition Californienne 65 Avertissements

    RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de FRÉQUENCE (H.F.) risque provoquer des interférences. provoquer des interférences. D L’énergie électromagnétique risque D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences pour l’équipement provoquer des interférences avec les équi- électronique sensible tel que les ordinateurs et l’équipement commandé...

  • Page 15: Section 3 − Definitions

    A complete Parts List is available at www.MillerWelds.com 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 Do not discard product (where applicable) with general waste.
  • Page 16 A complete Parts List is available at www.MillerWelds.com Do not weld on drums or any closed containers. Safe16 2012−05 Do not remove or paint over (cover) the label. Safe20 2012−05 Disconnect input plug or power before working on machine. Safe30 2012−05 Flying pieces of parts can cause injury.
  • Page 17 A complete Parts List is available at www.MillerWelds.com Environmental Protection Use Period (China) Safe123 2016−06 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. Safe38 2012−05 Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk...

  • Page 18: Miscellaneous Symbols And Definitions

    A complete Parts List is available at www.MillerWelds.com 3-2. Miscellaneous Symbols And Definitions Amperage Remote Negative Output Inductance Direct Current Foot Control (DC) Constant Current Gas Metal Arc Welding (GMAW) Arc Force Conventional Rated No Load Load Voltage Voltage (OCV) Rated Welding Hertz Current...

  • Page 19: Section 4 − Specifications

    A complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Features And Benefits LVCt Line Voltage Compensation is circuitry that keeps the power source output constant regardless of input pow- er fluctuation. Wind Tunnel Technologyt circulates air over components that require cooling, not over electronic circuitry, which reduces contaminants and improves reliability in harsh welding environments.

  • Page 20: Dimensions And Weight

    A complete Parts List is available at www.MillerWelds.com 4-5. 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.
  • Page 21 A complete Parts List is available at www.MillerWelds.com C. China EEP Hazardous Substance Information   ‡ China EEP Hazardous Substance Information Ö Hazardous Substance Component Name × (if applicable) PBDE Ö Brass and Copper Parts Coupling Devices Switching Devices Ö...

  • Page 22: Duty Cycle And Overheating

    A complete Parts List is available at www.MillerWelds.com 4-7. 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.

  • Page 23: Section 5 − Installation

    A complete Parts List is available at www.MillerWelds.com 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 24: 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 5-3. Weld Output Terminals Turn off power before connecting to weld output terminals.

  • Page 25: Connecting Weld Output Cables

    A complete Parts List is available at www.MillerWelds.com 5-4. Connecting Weld Output Cables Do not place anything between weld cable terminal and copper bar. Tools Needed: 3/4 in. (19 mm) Incorrect Installation 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...

  • Page 26: 115 Volts Ac Duplex Receptacle And Supplementary Protectors

    A complete Parts List is available at www.MillerWelds.com 5-6. 115 Volts AC Duplex Receptacle And Supplementary Protectors 115 V 7 Amp AC Receptacle Supplementary Protector CB1 Supplementary Protector CB2 CB1 protects duplex receptacle. CB2 protects 24 volts AC portion of Remote receptacle from...

  • Page 27: Optional Gas Valve Operation And Shielding Gas Connection

    A complete Parts List is available at www.MillerWelds.com 5-7. 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.

  • Page 28: Electrical Service Guide

    A complete Parts List is available at www.MillerWelds.com 5-8. 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 29 A complete Parts List is available at www.MillerWelds.com Notes OM-255083 Page 23...

  • Page 30: Connecting Input Power

    A complete Parts List is available at www.MillerWelds.com 5-9. Connecting Input Power = GND/PE Earth Ground Tools Needed: 5/16 in. Input5 2013−04 / Ref. 803 766-C / 257 348-A OM-255083 Page 24...
  • Page 31 A complete Parts List is available at www.MillerWelds.com 5-9. 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 5-2.

  • Page 32: Section 6 − General Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − GENERAL OPERATION 6-1. Front Panel 255 075-A / 246 917-B played for approximately three seconds 12 Power Switch Weld process operation sections de- after the arc is broken. 13 Remote PC Interface scribe functionality of the identified items.

  • Page 33: Mode Switch Settings

    A complete Parts List is available at www.MillerWelds.com 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 Remote 14 Amps % Panel Amps* Scratch Start TIG GTAW Remote 14...

  • Page 34: Configuration Option Menu

    A complete Parts List is available at www.MillerWelds.com 6-3. Configuration Option Menu 255 075-A Mode Switch Setup Right Displays. SET−UP will be displayed momentarily. Remote 14 Receptacle The Configuration Option Menu provides a Configuration options are displayed in the Left Left Display means to customize some machine features Display.
  • Page 35 XMT 450 MPa and synergic feeders allow single knob control of the arc. As wirefeed speed is increased or decreased, the pulse parameters increase or decrease matching the power output to the wire speed.
  • Page 36 A complete Parts List is available at www.MillerWelds.com Configuration Option Menu (Continued) Revision Information INFO This option identifies the unit’s weld library (INFO LIB) and firmware revision (INFO REV). Press the Setup Button while the unit is display- ing INFO LIB to identify the unit’s weld library. Press the Setup Button while the unit is display- ing INFO REV to identify the unit’s firmware revi- sion.

  • Page 37: Section 7 − Gtaw Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − GTAW OPERATION 7-1. Typical Connection For GTAW Process Ref. 250 032-B 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.

  • Page 38: Scratch Start Tig Welding Mode - Gtaw Process

    A complete Parts List is available at www.MillerWelds.com 7-2. Scratch Start TIG Welding Mode - GTAW Process 84. 5 255 075-A 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 39: Lift-Arc Tig Welding Mode - Gtaw Process

    A complete Parts List is available at www.MillerWelds.com 7-3. Lift-Arc TIG Welding Mode - GTAW Process 255 075-A 1 − 2 “Touch” Seconds Do NOT Strike Like A Match! tion as shown. workpiece at weld start point. Slowly lift Weld terminals energized electrode.

  • Page 40: Remote Scratch Start Tig Welding Mode - Gtaw Process

    A complete Parts List is available at www.MillerWelds.com 7-4. Remote Scratch Start TIG Welding Mode - GTAW Process 255 075-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.

  • Page 41: Section 8 − Gmaw/Gmaw-P/Fcaw Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 8 − GMAW/GMAW-P/FCAW OPERATION 8-1. Typical Connection For Remote Control Feeder GMAW/GMAW-P/FCAW Process Ref. 250 033-B Workpiece Use of shielding gas is dependant on Wire Turn off power before making Type. connections.

  • Page 42: Mig Welding Mode - Gmaw/Fcaw Process

    A complete Parts List is available at www.MillerWelds.com 8-2. MIG Welding Mode - GMAW/FCAW Process 25. 0 255 075-A Press the Setup Button to confirm the Weld terminals energized The preset voltage can be adjusted re- selection. The unit will acknowledge a through the remote control in MIG motely at the wire feeder if the feeder change of wire and gas information by dis-...

  • Page 43: Mig - Wire And Gas Selection Table

    A complete Parts List is available at www.MillerWelds.com 8-3. MIG - Wire and Gas Selection Table WIRE TYPES** GAS TYPES DEFAULT INDUCTANCE .035 (0.9) STL ARGN CO2 (ARGON / CARBON DIOXIDE) .045 (1.2) STL ARGN OXY (ARGON / OXYGEN) .052 (1.4) STL Steel 1/16 (1.6) STL ARGN CO2 (ARGON / CARBON DIOXIDE)

  • Page 44: Pulsed Mig Welding Mode - Gmaw-P Process

    A complete Parts List is available at www.MillerWelds.com 8-4. Pulsed MIG Welding Mode - GMAW-P Process 25.0 255 075-A Pulsed MIG − Wire and Gas Selection Arc Length - Pulsed MIG Manual Control Weld terminals energized Table for available wires and gases (see Section 6-3) through the remote control in (see Section 8-5).

  • Page 45: Pulsed Mig - Wire And Gas Selection Table

    A complete Parts List is available at www.MillerWelds.com 8-5. Pulsed MIG - Wire and Gas Selection Table WIRE TYPES* GAS TYPES .035 (0.9) STL .045 (1.2) STL ARGN CO2 (ARGON / CARBON DIOXIDE) ARGN OXY (ARGON / OXYGEN) .052 (1.4) STL 1/16 (1.6) STL .030 (0.8) STL Steel...

  • Page 46: Remote Process Select

    A complete Parts List is available at www.MillerWelds.com 8-6. Remote Process Select This power source can be used with wire feeders that support Remote Process Se- lect. This feature allows the operator to switch the active welding process between MIG and Pulsed MIG at the wire feeder. To determine if the welding system is Remote Process Select capable, connect the wire feeder to the power source and review the...

  • Page 47: Typical Connection For Voltage-Sensing Feeder Gmaw/Gmaw-P/Fcaw Process

    A complete Parts List is available at www.MillerWelds.com 8-7. Typical Connection For Voltage-Sensing Feeder GMAW/GMAW-P/FCAW Process Ref. 250 034-B Turn off power before making con- The connection diagram illustrates nections. Gun Trigger Receptacle DCEP (reverse polarity) suitable for Wire Feeder Positive (+) Weld Output Terminal all wires except self-shielded FCAW.

  • Page 48: V-Sense Feeder Welding Mode - Gmaw/Fcaw Process

    A complete Parts List is available at www.MillerWelds.com 8-8. V-Sense Feeder Welding Mode - GMAW/FCAW Process 255 075-A Operation Rotate Adjust Control to select desired gas. Weld terminals are energized at all times in V-Sense Feeder welding While the Volts Indicator is lit under the Left Press the Setup Button again to confirm the mode.

  • Page 49: V-Sense Feeder Welding Mode - Gmaw-P Process

    A complete Parts List is available at www.MillerWelds.com 8-9. V-Sense Feeder Welding Mode - GMAW-P Process R200 R200 Ref. 255 075-A ment of Arc Control, Wire Type, Gas Type Higher settings narrow the arc cone, re- Weld terminals are energized at all and Arc Length.

  • Page 50: Section 9 − Smaw/Cac-A Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 9 − SMAW/CAC-A OPERATION 9-1. Typical Connection For SMAW And CAC-A Process Ref. 250 035-B cutting torch to to positive weld output ter- Connect desired remote control to remote Turn off power before making con- minal.

  • Page 51: Stick Remote Welding Mode - Smaw/Cac-A Process

    A complete Parts List is available at www.MillerWelds.com 9-2. Stick Remote Welding Mode - SMAW/CAC-A Process 255 075-A Programmable Hot Start Weld terminals energized If the remote control has an amperage through the remote control in Stick adjustment, the adjustment will func- Remote welding mode.

  • Page 52: Stick Welding Mode - Smaw/Cac-A Process

    A complete Parts List is available at www.MillerWelds.com 9-3. Stick Welding Mode - SMAW/CAC-A Process 84. 5 255 075-A Right Display, the Adjust Control is used to Programmable Hot Start Weld terminals are energized at all set desired preset amperage. times in Stick welding mode.

  • Page 53: Optional Low Open Circuit Voltage (Ocv) Welding Modes

    A complete Parts List is available at www.MillerWelds.com 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 (See Section 6-3).

  • Page 54: Section 10 − Maintenance & Troubleshooting

    A complete Parts List is available at www.MillerWelds.com 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...

  • Page 55: Removing Case And Measuring Input Capacitor Voltage In 400 Vac Models

    A complete Parts List is available at www.MillerWelds.com 10-3. Removing Case and Measuring Input Capacitor Voltage In 400 VAC Models Turn Off welding power source, and disconnect in- put power. Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage as shown to be sure Typical Bleeder Resistor the input capacitors have...

  • Page 56: Help Displays

    A complete Parts List is available at www.MillerWelds.com 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 HELP Indicates a malfunction in the primary power circuit.

  • Page 57: Troubleshooting

    A complete Parts List is available at www.MillerWelds.com 10-5. Troubleshooting Trouble Remedy No weld output; unit completely inop- Place line disconnect switch in On position (see Section 5-9). erative. 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).

  • Page 58: Section 11 − Electrical Diagram

    SECTION 11 − ELECTRICAL DIAGRAM Figure 11-1. Circuit Diagram OM-255083 Page 52...
  • Page 59 253 457-C OM-255083 Page 53...
  • Page 60 Notes...
  • Page 61 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org...
  • Page 62 Notes...
  • Page 63 Effective January 1, 2016 (Equipment with a serial number preface of MG 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 64 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 2016 Miller Electric Mfg. Co. 2016−01...

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