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Miller Electric XMC 4000, Owner'S Manual

The Miller Electric XMC 4000 Owner's Manual is available for free download on our website. This comprehensive manual provides detailed instructions on how to operate and maintain your XMC 4000, ensuring optimal performance and longevity. Download the manual from manualshive.com today and get the most out of your Miller Electric product.

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OM-221 694 Page 37

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 8-2. Unit Main Assembly

Quantity

18

CR5,6,R1

0001751940

Resistor/Capacitors

1

. . . 

. . . 

. . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19

D1,2

000201531

Kit Diode, secondary circuit

1

. . . 

. . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20

PC6

000185697

Circuit Board, EMI filter

1

. . . 

. . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21

HD1

000189567

Transducers, current 300A

1

. . . 

. . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

22

RT2

000173632

Thermistor, NTC 30k ohms

2

. . . 

. . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

23

V56120010

Conveyor

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

24

V56018092

Nut, cable holder

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

25

056061042

Solenoid valve 24 VAC

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

26

V16118004

Rear panel

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

27

V56091091

Cable holder

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

28

V56014026

Handle, security

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

29

V57014066

Main cable, 4m

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

30

T1

000179616

Transformer, HF

1

. . . 

. . . . . . . 

. . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

31

L1

000173563

Inductor, input

1

. . . 

. . . . . . . 

. . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

32

Z1

000173570

Stabilizer

1

. . . 

. . . . . . . 

. . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

33

T4

V58021080

aux transformer

1

. . . 

. . . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

34

WCP

V57010072

Motor, 115 VAC 120 W

1

. . . 

. . . . . 

. . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

35

V57011071

Pump, 3/8” gas

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

36

WCF

V56126035

Fan motor 115 VDC

1

. . . 

. . . . . 

. . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

37

V56031027

Radiator support

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

38

V56082001

Radiator

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

39

056061049

Pressure switch

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

40

C1

000188446

Capacitor, 5 uf 900 VDC

1

. . . 

. . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

41

V56031027

Water cooling box

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

42

000176106

Label, warning fan

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

43

V27042020

Tank, 8 L

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

44

PC2

000212210

Circuit board, interconnect

1

. . . 

. . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

45

C3,4

000192935

Capacitor, 2700 uf 450 VDC

2

. . . 

. . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

46

SR1

000179629

Kit Diode, primary circuit

1

. . . 

. . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

47

PM1,2

000208173

Kit, IGBT

1

. . . 

. . . . . 

. . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

48

000197555

tool tray

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

49

V56161034

Reel holder

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

50

CB2

000083432

Circuit breaker, 10 A 250 VAC

1

. . . 

. . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

51

CB1

000161078

Circuit breaker, 7 A 250 VAC

1

. . . 

. . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

52

PC7

V57084045

Circuit board, motor

1

. . . 

. . . . . . 

. . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

53

RL1

000006393

Relay, 24 VAC

1

. . . 

. . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

54

PC1

000215042

Circuit board, control

1

. . . 

. . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

55

V560050008

Circuit board support

1

. . . 

. . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

56

T2

000195829

Transformer, control

1

. . . 

. . . . . . . 

. . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

57

V57060005

Baffle plate

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

58

000178937

Label, warning gears

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

59

V56014017

Board protection

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

60

V56005009

Motor support

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

61

028066243

Wire drive system w/encoder motor

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . 

62

V57052030

Euroadapter

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

63

V56005028

Flange euroadapter

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

64

S1

000128756

Switch, 40 A 600 VAC

1

. . . 

. . . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

65

V16118003

Front panel

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

66

V57094063

Receptacle kit, 7 pin

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

67

000129525

Power connector

2

. . . 

. . . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

68

V16006002

Base

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

69

M

V56126046

Fan motor 24 VDC

1

. . . 

. . . . . . . 

. . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

70

V56005012

Fan bracket

1

. . . 

. . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

71

000193919

Knob, pointer

2

. . . 

. . . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

72

PC3

V57084081

Circuit board, control

1

. . . 

. . . . . . 

. . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

73

556049368

Red fast coupling connector

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

74

556048369

Blue fast coupling connector

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

V28066079

Kit, water coolant

1

. . . . . . . . . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

♦

Optional

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Summary of Contents for XMC 4000

Page 1: ...Processes Multiprocess Welding OM 221 694B 2006 07 Description Arc Welding Power Source XMC 4000 400 Volts R...

Page 2: ...ucts Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you...

Page 3: ...rgic Pulsed MIG Welding 17 4 5 Wire Diameter Selection In Synergic MIG Or Synergic Pulsed MIG Welding 17 4 6 Trigger Mode Selection 18 4 7 Inductance Material Thickness And Gas Selection In Manual MIG...

Page 4: ...MCR 4000 conforms to the following Directives and Standards Directives Electromagnetic compatibility Directives 89 336 EEC 92 31 EEC Low Voltage Directive 73 23 EEC Machinery Directives 89 392 EEC and...

Page 5: ...0 147 see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that inpu...

Page 6: ...mbustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguishe...

Page 7: ...s computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt l...

Page 8: ...Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent...

Page 9: ...move fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a...

Page 10: ...vicing unit 9 After taking proper precautions as shown connect power to unit S 185 836 60 s V V V 1 2 3 4 5 6 7 8 9 A A Warning Watch Out There are possible hazards as shown by the symbols B Electric...

Page 11: ...n filter and check condition of hoses 6 Read Owner s Manual 7 Use coolant suggested by manufacturer B 050024004 1 Warning Watch Out There are possible hazards as shown by the symbols 2 Falling unit ca...

Page 12: ...tant Current Inductance Increase Three Phase Static Frequency Con verter Transformer Rectifier Gas Metal Arc Welding GMAW Shielded Metal Arc Welding SMAW Recycle or dispose of used coolant in an envir...

Page 13: ...0 09 11 5 0 04 While idling 6 Minutes Welding 4 Minutes Resting 3 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit ove...

Page 14: ...Ampere Curves va_curve1 4 95 SA 178 652 SA 178 653 Volt amperecurves show minimum and maximum voltage and amper age output capabilities of unit Curves of other settings fall be tween curves shown A CC...

Page 15: ...t power needs 3 Line Disconnect Device Locate unit near correct input power supply Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Sect...

Page 16: ...100 Duty Cycle 10 100 Duty Cycle 100 20 20 20 30 35 50 60 60 MIG connector 150 30 30 35 50 60 70 95 95 MIG connector 200 30 35 50 60 70 95 120 120 250 35 50 60 70 95 120 2 70 2 70 300 50 60 70 95 120...

Page 17: ...Unscrew cap from tank Use table to select proper coolant and fill tank until coolant appears in upper half of indicator Check coolant level after attaching torch coolant hoses and running cooler Be su...

Page 18: ...s are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies c...

Page 19: ...ays values and parameters for se lected welding process 11 E1 Encoder Control 1 Use control to change values and parame ters that appear on D1 12 E2 Encoder Control 2 Use control to change values and...

Page 20: ...default is 0 0 T range is 5 0 T to 5 0 T D2 value is wire feed speed from minimum to maximum value according to welding curve selection When L2 is flashing material transfer in the arc is by large dr...

Page 21: ...g AlMg AlMg5 or AlSi AlSi5 Special allows selecting cored wire or spe cial wire abbreviations for the different wire types will appear on D1 and D2 Be aware that the wire type selection is retained in...

Page 22: ...ops L14 ON selects 4 times trigger function When trigger is pressed welding starts When trigger is released welding contin ues When trigger is pressed and released a second time welding stops L15 ON s...

Page 23: ...D2 shows gas abbreviation Use E2 to change gas type This setting is stored in process memory LED will turn off after several seconds and D1 and D2 will return to main display L17 L18 L19 P7 4 8 Jog An...

Page 24: ...elected process parameter values Setup allows viewing and changing default parametervalues for all welding processes for the desired weld characteristics D1 shows the welding parameter D2 shows the pa...

Page 25: ...g P3 push button Purge air from gun gas hose using P8 push button see Section 4 8 5 6 2 3 1 4 12 Selecting Manual MIG Welding Set Manual MIG welding process using P3 push button In Manual MIG mode the...

Page 26: ...default wire feed speed setting of 5 0 m min minimum MIN maximum MAX or default DEF values are arbi trary based on set welding data Set wire feed speed in meters min M Select wire type using P4 push...

Page 27: ...to POSG D2 value is default setting of 0 1 s range is 0 0 s to 10 0 s Use E2 to change D2 value Setting BurnBack Use E1 to change D1 to BURN D2 value is default setting of Auto range is 1 to 200 Auto...

Page 28: ...a longer and hotter arc Lower values produce a shorter and cooler arc Recommended value for trim is default setting or near 0 0T Trim setting may vary by a greater amount depending on welding posi ti...

Page 29: ...bead appearance especially on aluminum The Synergic Double Pulsed MIG process allows control all parameters to produce high quality welds on aluminum Incorrect settings in Synergic Double Pulsed Weldi...

Page 30: ...n 4 8 Select trigger mode using P6 push button see Section 4 6 4 19 TIG Welding Advanced Settings Setting Initial And Final Amperage To set initial and final amperage proceed as follows Press P2 to en...

Page 31: ...y precautions according to Section 1 Prepare unit according Section 3 Using a cable with a proper adapter con nect electrode holder to the MIG gun con nector Connect work clamp cable to the WORK conne...

Page 32: ...s 3 Months Replace Damaged Or Unreadable Labels Clean And Tighten Weld Terminals Replace Damaged Gas Hose Repair Or Replace Cracked Cables And Cords 6 Months Clean Drive Rolls Blow Out Or Vacuum Insid...

Page 33: ...c power supply to water cooler from overload If CB7 opens water cooler stops op erating 2 Circuit Breaker CB10 Protects 24 volts ac power supply to wire feeder from overload If CB10 opens wire feeding...

Page 34: ...et circuit breaker CB10 see Section 5 3 Check and clear any restrictions at drive assembly and liner Secure gun plug in receptacle or repair leads or replace trigger switch Coolant system not working...

Page 35: ...OM 221 694 Page 31 5 5 Help Displays D2 D1 D2 D1 D2 D1 HELP 0 D2 D1 D2 D1 D2 D1 D2 D1 D2 D1 HELP 1 HELP 2 HELP 3 HELP 4 D2 D1 HELP 5 D2 D1 HELP 6 HELP 8 HELP 9 HELP 15 D2 D1 HELP 7 D2 D1 HELP 50...

Page 36: ...ut voltage is too low and unit has automaticallyshut down Operation will con tinue when voltage is within an acceptable lower range limit 15 below acceptable in put voltage Contact an electrician to c...

Page 37: ...OM 221 694 Page 33 SECTION 6 ELECTRICAL DIAGRAM January 26 2005...

Page 38: ...OM 221 694 Page 34 SECTION 7 PARTS LIST Hardware is common and not available unless listed 10 11 12 13 14 15 16 17 February 11 2005 Figure 8 1 Unit Outer Assembly...

Page 39: ...07235 Label warning tilting 1 6 V56142088 Label rating plate 1 7 000207290 Label warning cooling unit 1 8 656043030 Cap 2 9 056054067 Rubber wheel D 250mm 2 10 156012113 Wheel pivot 1 11 V16121013 Cov...

Page 40: ...OM 221 694 Page 36 Hardware is common and not available unless listed February 11 2005 Figure 8 2 Unit Main Assembly...

Page 41: ...6 SR1 000179629 Kit Diode primary circuit 1 47 PM1 2 000208173 Kit IGBT 1 48 000197555 tool tray 1 49 V56161034 Reel holder 1 50 CB2 000083432 Circuit breaker 10 A 250 VAC 1 51 CB1 000161078 Circuit b...

Page 42: ...Notes...

Page 43: ...shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Miller but manufactured...

Page 44: ...stal Code Please complete and retain with your personal records Owner s Record Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and C...

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