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Miller XMT 450 CC/CV Owner'S Manual Download Page 40

OM-251387 Page 36

SECTION 9 

−

 SMAW/CAC-A OPERATION

6

3

4

2

1

9-1. Typical Connection For SMAW And CAC-A Process

252926-C

!

Turn off power before making con-

nections.

1

Electrode Holder 

(Carbon Arc)

For CAC-A process connect carbon arc

cutting torch to to positive weld output ter-

minal.
2

Electrode Holder

3

Positive (+) Weld Output Terminal

4

Remote 14 Receptacle

Connect desired remote control to remote

14 receptacle as required.
5

Compressed Air LIne

6

Negative (

−

) Weld Output Terminal

7

Workpiece

5

7

Summary of Contents for XMT 450 CC/CV

Page 1: ... Welding Power Source XMT 450 CC CV OM 251387S 2020 04 Processes Description Multiprocess Welding File MULTIPROCESS R For product information Owner s Manual translations and more visit www MillerWelds com ...

Page 2: ...products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety Precautions They will help you protect yourself against potential hazards on the worksite We ve made installation a...

Page 3: ...Arc Controls 11 4 3 Serial Number And Rating Label Location 11 4 4 Software Licensing Agreement 11 4 5 Information About Default Weld Parameters And Settings 11 4 6 Unit Specifications 11 4 7 Dimensions and Weight 12 4 8 Environmental Specifications 12 4 9 Duty Cycle and Overheating 13 4 10 Volt Ampere Curves 14 SECTION 5 INSTALLATION 15 5 1 Selecting A Location 15 5 2 Selecting Input Voltage 230 ...

Page 4: ... FCAW Process 35 SECTION 9 SMAW CAC A OPERATION 36 9 1 Typical Connection For SMAW And CAC A Process 36 9 2 CC Welding Mode SMAW CAC A Process 37 9 3 Stick Welding Mode SMAW CAC A Process 38 9 4 Optional Low Open Circuit Voltage OCV Welding Modes 39 9 5 Alternate Configuration Functions 39 SECTION 10 MAINTENANCE TROUBLESHOOTING 40 10 1 Routine Maintenance 40 10 2 Blowing Out Inside Of Unit 40 10 3...

Page 5: ...llow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomati...

Page 6: ...not possible tightly cover them with approved covers D Do not weld where flying sparks can strike flammable material D Protect yourself and others from flying sparks and hot metal D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas D Watch for fire and keep a fire extinguisher nearby D Be aware that welding on a ceiling fl...

Page 7: ...to move unit be sure forks are long enough to extend beyond opposite side of unit D Keep equipment cables and cords away from moving vehicles when working from an aerial location D Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING D Allow cooling period follow r...

Page 8: ...cuments Website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protection Association Website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association Website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Website www csagrou...

Page 9: ... de la fonction de télécommande si l appareil en est équipé D D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliques telles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou s il y a un risque élevé de contact inévitab...

Page 10: ...udure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incen dies et des brûlures Le contact accidentel de l électrode avec des objets métalliques peut provoquer des étincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage vérifier et s assurer que l endroit ne présente pas de danger D Déplacer toutes les substances inflamma...

Page 11: ...e mettre l appareil en service LA CHUTE DE L ÉQUIPEMENT peut provoquer des blessures D Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire D Utilisez les procédures correctes et des équipements d une capa cité appropriée pour soulever et supporter l appareil D En utilisant des fourches de levage pour déplacer l unité s...

Page 12: ...ards Institute Website www ansi org Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents Website www global ihs com Safe Practices for Welding and Cutting Containers that have Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents Website www global ...

Page 13: ...long sleeves and button your collar when servicing unit Safe28 2012 05 After taking proper precautions as shown connect power to unit Safe29 2012 05 Disconnect input plug or power before working on machine Safe30 2012 05 5min V V V Hazardous voltage remains on input capacitors after power is turned off Do not touch fully charged capacitors Always wait 5 minutes after power is turned off before wor...

Page 14: ...ted Welding Cur rent Panel Single Phase Increase Circuit Breaker Positive Constant Voltage U1 Primary Voltage IP Degree Of Protection Lift Arc Trigger Hold Operation GTAW I1eff Maximum Effective Supply Current Voltage Sensing Feeder Output Off Direct Current DC Constant Current S Suitable For Weld ing In An Environ ment With In creased Risk Of Electric Shock U0 Rated No Load Volt age OCV Hz Hertz ...

Page 15: ... power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 4 4 Software Licensing Agreement The End User License Agreement and any third party notices and terms and conditions pertaining to third party software can be found at https www millerwelds com eula and are incorporated by reference herein 4 5 Information About Default We...

Page 16: ...m E 2 3 4 in 70 mm F 3 3 8 in 86 mm Dia G 1 4 20 UNC 2B Thread Weight 109 lb 49 4 kg 4 8 Environmental Specifications A IP Rating IP Rating IP23 This equipment is designed for outdoor use IP23 2017 02 B Temperature Specifications Operating Temperature Range Storage Transportation Temperature Range 14 to 104 F 10 to 40 C Output is derated at temperatures above 104 F 40 C 4 to 131 F 20 to 55 C Temp1...

Page 17: ...ns output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty Overheating 0 15 A V OR Reduce Duty Cycle Minutes duty1 4 95 SA 181 560 250 541 A Continuous Welding 100 Duty Cycle At 450 Amperes 60 Duty Cycle At 580 Amperes 6 Minutes Welding 4 Minutes Resting ...

Page 18: ...g power source Curves of other set tings fall between curves shown AMPERAGE VOLTAGE CC Mode VOLTAGE CV MODE AMPERAGE 0 20 40 60 80 100 0 100 200 300 400 500 600 700 MAX MIN 252918 A 252919 A 0 20 40 60 80 100 0 100 200 300 400 500 600 10 30 50 70 90 TIG REMOTE TIG SCRATCH TIG MAX STICK MAX STICK 80A TIG MIN 100 0 25 50 75 ARC CONTROL DIG ...

Page 19: ...Forks Extend forks beyond opposite side of unit 2 Lifting Handles Use handles to lift unit 3 Hand Cart Use cart or similar device to move unit 4 Line Disconnect Device Locate unit near correct input power supply 5 1 Selecting A Location 4 18 in 460 mm 18 in 460 mm OR 1 Movement Location And Airflow 2 3 2 Do not move or operate unit where it could tip loc_med 2015 04 Notes ...

Page 20: ... Window Check voltage selected in unit Changing selection is only neces sary if selected value does not match available input voltage 2 Relinking Board PC6 3 Mounting Screws 4 Receptacle RC8 Connection For 230 VAC Input Power 5 Receptacle RC7 Connection For 460 VAC Input Power Move relinking board as needed and connect plug PLG4 in unit to RC8 or RC7 according to input power voltage 1 Tools Needed...

Page 21: ...0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 2x4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 2x4 0 2x120 500 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 3x3 0 3x95 3x3 0 3x95 600 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 3x3 0 3x95 3x4 0 3x120 3x4 0 3x120 This chart is a general guideline and may not suit all applications If cable overheats...

Page 22: ... copper bar are clean Tools Needed 3 4 in 19 mm 4 2 3 Do not place anything between Incorrect Installation 1 weld cable terminal and copper bar 5 6 Remote 14 Receptacle Information A J B K I C L N H D M G E F Ref 252018 C Socket Socket Information 24 VOLTS AC A 24 volts AC Protected by supplementary protect or CB2 B Contact closure to A completes 24 volts AC con tactor control circuit REMOTE CONTR...

Page 23: ...51387 Page 19 5 7 Supplementary Protector 252020 B 1 Supplementary Protector CB2 CB2 protects 24 volts AC portion of Remote 14 receptacle from overload Press button to reset supplement ary protector 1 Notes ...

Page 24: ...itting Connect hose coupler to torch Connect one end of gas hose to hose coupler Connect remaining end of gas hose to Gas Out fitting Operation The gas solenoid controls gas flow during the TIG process as follows Remote TIG Gas flow starts with remote contac tor on Gas flow stops at end of post flow if current was detected or with re mote contactor off if no current was detected Lift Arc TIG Gas f...

Page 25: ...10 64 Raceway Installation Minimum Supply Conductor Size In AWG mm2 5 6 16 10 6 0 Minimum Grounding Conductor Size In AWG mm2 5 8 10 10 6 0 Flexible Cord Installation Minimum Supply Conductor Size In AWG mm2 6 4 25 8 10 Minimum Outside Diameter Of Cord In Inches mm 0 865 22 0 865 22 Maximum Outside Diameter Of Cord In Inches mm 1 260 32 1 260 32 Recommended Strain Relief 7 See Parts List See Parts...

Page 26: ...OM 251387 Page 22 5 10 Connecting Input Power Tools Needed 5 16 in Input5 2013 04 Ref 803766 C 218005 A L1 L2 L3 1 2 3 6 4 5 7 GND PE Earth Ground L1 8 1 L2 L3 3 5 9 7 10 11 ...

Page 27: ...f of proper size for unit and input conductors Route conductors cord through strain relief Tighten strain relief 3 Contactor W1 4 Welding Power Source Grounding Terminal 5 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to machine grounding terminal first 6 Welding Power Source Line Terminals 7 Input Conductors L1 L2 L3 Connect input conductors L1 L2 and...

Page 28: ...mote 14 Receptacle 2 Left Display 3 Right Display The meters display the actual weld output values after arc initiation and remains dis played for approximately three seconds after the arc is broken 4 Adjust Control 5 Power Switch 6 Arc Control 7 Optional Gas Valve Knockout 8 Mode Switch 9 Weld Output Terminal 10 Weld Output Terminal 252022 A 251142 A 9 2 3 8 1 5 4 6 7 10 ...

Page 29: ... GTAW Electrode Hot Amps Panel Amps TIG GTAW Remote 14 Amps Panel Amps MIG GMAW Remote 14 Volts Volts Pulsed MIG GMAW P Remote 14 N A Arc Length 0 100 CC SMAW CAC A Remote 14 Amps Panel Amps Stick SMAW CAC A Electrode Hot Amps Panel Amps V Sense Feeder GMAW Electrode Hot Volts Volts Requires an external pulsing device See Section 9 5 Alternate Configuration Functions Notes ...

Page 30: ...efore making con nections 1 Foot Control 2 Positive Weld Output Terminal 3 Remote 14 Receptacle Connect desired remote control to Remote 14 receptacle if required 4 Gas In Connection Optional 5 Gas Cylinder 6 Gas Out Connection Optional 7 Negative Weld Output Terminal 8 TIG Torch 9 Workpiece 3 7 4 2 6 1 8 5 9 ...

Page 31: ...n as shown The open circuit voltage is shown in the Left Display Preset amperage is shown in the Right Display Operation The Adjust Control is used to set desired preset amperage If a remote control is used for amper age adjustment the adjustment will function as a percentage of the preset amperage For best results gently scratch the tungsten electrode to the work to initi ate an arc To minimize a...

Page 32: ... instead a low sensing voltage is present The sensing voltage allows the electrode to touch the workpiece without overheating sticking or getting contami nated Operation The Adjust Control is used to set desired preset amperage If a remote control is used for amper age adjustment the adjustment will function as a percentage of the preset amperage For best results firmly touch the tung sten electro...

Page 33: ...e preset amperage is shown in the Right Display Operation The Adjust Control is used to set desired preset amperage A remote control is required to turn on the weld output If the remote control has an amperage adjustment the adjustment will func tion as a percentage of the preset am perage For best results gently scratch the tungsten electrode to the work to initi ate an arc To minimize arc flare ...

Page 34: ... Positive Weld Output Terminal 3 Negative Weld Output Terminal 4 Ground Cable to Workpiece 5 Workpiece 6 Gun 7 Wire Feeder 8 Gas Hose 9 Gas Cylinder Use of shielding gas is dependant on Wire Type The connection diagram illustrates DCEP reverse polarity suitable for all wires except self shielded FCAW The majority of self shielded FCAW wires require DCEN straight polarity 3 4 5 6 7 8 9 1 2 ...

Page 35: ...lay Operation The Adjust Control is used to set desired preset voltage The preset voltage can be adjusted re motely at the wire feeder if the feeder has a voltage control This voltage con trol will override the Adjust Control of preset voltage on the welding power source Arc Control Inductance Rotate Arc Control to select desired induc tance setting from 0 to 100 Use lower in ductance settings to ...

Page 36: ...ative Weld Output Terminal 5 Ground Cable to Workpiece 6 Workpiece 7 Gun 8 Wire Feeder 9 Gas Hose 10 Gas Cylinder Use of shielding gas is dependant on Wire Type The connection diagram illustrates DCEP reverse polarity suitable for all wires except self shielded FCAW The majority of self shielded FCAW wires require DCEN straight polarity Flux cored wires are not pulsed No pulse program available fo...

Page 37: ... Left Display 3 Right Display 4 Adjust Control Setup For typical system connections refer to Section 8 3 Rotate Mode Switch to PULSED MIG posi tion as shown Left and Right Display will show PPP PPP Operation This unit requires an external pulsing device like an Optima to pulse MIG weld See Optima owner s manual for more in formation 251142 A 2 3 1 4 PP P PPP ...

Page 38: ...t Terminal 3 Ground Cable to Workpiece 4 Workpiece 5 Voltage Sensing Clamp 6 Gun 7 Gun Trigger Receptacle 8 Wire Feeder 9 Gas Hose 10 Gas Cylinder Use of shielding gas is dependant on Wire Type The connection diagram illustrates DCEP reverse polarity suitable for all wires except self shielded FCAW The majority of self shielded FCAW wires require DCEN straight polarity 2 3 9 10 8 7 5 6 4 1 ...

Page 39: ...tion as shown The Left Display toggles between open cir cuit voltage and preset voltage Operation The Adjust Control is used to set desired preset voltage The Left Display toggling momentarily pauses while the preset voltage is ad justed Arc Control Inductance Rotate Arc Control to select desired induc tance setting from 0 to 100 Use lower in ductance settings to stiffen the arc and re duce puddle...

Page 40: ...ing con nections 1 Electrode Holder Carbon Arc For CAC A process connect carbon arc cutting torch to to positive weld output ter minal 2 Electrode Holder 3 Positive Weld Output Terminal 4 Remote 14 Receptacle Connect desired remote control to remote 14 receptacle as required 5 Compressed Air LIne 6 Negative Weld Output Terminal 7 Workpiece 5 7 ...

Page 41: ...trol preset will be dis played in the amperage window See section 9 5 for more information re garding Alternate Configuration Func tionality Adaptive Hot Start automatically increases welding amperage at the start of a weld This helps eliminate electrode sticking dur ing arc initiation For best results at the end of the weld pull back the electrode quickly to extin guish the arc Arc Control Dig Ro...

Page 42: ... will be ignored and amperagewill operate in panel only control See section 9 5 for more information re garding Alternate Configurations Adaptive Hot Start automatically increases welding amperage at the start of a weld This helps eliminate electrode sticking dur ing arc initiation For best results at the end of the weld pull back the electrode quickly to extin guish the arc Arc Control Dig Rotate...

Page 43: ...figuration 2 is selected Stick mode operates in Panel Only control meaning any remote control that is plugged into the remote 14 control will be ignored and have no effect on the output When Stick mode is active a decimal point will be displayed in the amperage window Configuration 3 changes how the display works in the CC mode When configuration 3 is selected the amperage window will display the ...

Page 44: ...lace To be done by Factory Authorized Service Agent Every 3 Months nl Labels l Cracked Torch Body Every 3 Months nΔ lCables And Cords Every 3 Months n Clean And Tighten Weld Connections Every 6 Months Durning heavy service clean monthly 10 2 Blowing Out Inside Of Unit Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown 252018 C...

Page 45: ...drops to near 0 zero volts If the capacitor voltage does not drop to near zero after sev eral minutes use a bleeder re sistor of between 25 and 1000 ohms at least 5 watts 16 AWG 1000 volts DC insulating rating wire to discharge the ca pacitor s 4 Typical Bleeder Resistor An example of a typical bleeder re sistor is shown on this page Proceed with job inside unit Rein stall right side panel when fi...

Page 46: ...on will continue when the unit has cooled Help 5 Display Indicates the right side of the unit has over heated The unit has shut down to allow the fan to cool it see Section 4 9 Operation will continue when the unit has cooled Help 6 Display Indicates a malfunction in the input circuitry of the unit If this display is shown contact a Factory Authorized Service Agent Help 8 Display Indicates a malfu...

Page 47: ...ctions see Section 5 10 No weld output meter display On Input voltage outside acceptable range of variation see Section 5 9 Check repair or replace remote control Unit overheated Allow unit to cool with fan On see Section 4 9 Erratic or improper weld output Use proper size and type of weld cable see Section 5 3 Clean and tighten all weld connections Check for correct polarity No 24 volts AC output...

Page 48: ...OM 251387 Page 44 SECTION 11 ELECTRICAL DIAGRAM Figure 11 1 Circuit Diagram ...

Page 49: ...OM 251387 Page 45 263 254 B ...

Page 50: ...N 12 PARTS LIST Hardware is common and not available unless listed 2 10 9 8 7 6 5 4 3 1 12 20 19 18 17 16 15 14 13 11 22 30 29 28 27 26 25 24 23 21 40 39 38 37 36 35 34 33 32 31 47 46 45 44 43 42 41 Figure 12 1 Parts Assembly ...

Page 51: ...OM 251387 Page 47 252023 E 81 82 83 84 85 86 48 49 60 59 58 57 56 55 54 53 52 51 50 61 70 69 68 67 66 65 64 63 62 54 72 80 79 78 77 76 75 74 73 71 ...

Page 52: ...3 T1 263252 XFMR HF 1 24 249110 Base 1 25 269262 Insulator Base Bus Bar 1 26 229325 Foot Mtg Unit 4 27 176736 Screw Mtg Foot 4 28 PC3 251315 Circuit Card Assy Front Pnl Dspl W Program 1 PLG 18 250065 Plug W Leads Voltage Feedback RC2 1 PLG 21 136810 Housing Plug Pins Service Kit 1 RC 21 167640 Housing Plug Pins Service Kit 1 29 S1 244920 Switch Tgl 3Pst 40A 600VAC Scr Term Wide Tgl 1 30 176226 Ins...

Page 53: ...1 72 C1 2 280914 Capacitor Polyp Film 34 UF 1700 VRMS 10 2 73 185992 Bus Bar Capacitor 2 74 PC2 236049 Circuit Card Assy Interconnecting With Components 1 PLG 11 131056 Housing Plug Pins Service Kit RC7 8 1 PLG 12 115093 Housing Plug Pins Service Kit RC2 1 PLG 13 115091 Housing Plug Pins Service Kit RC9 1 75 PC6 249114 Circuit Card Assy Relink 1 76 218566 Gasket Inductor Mounting E70 Ferrite Core ...

Page 54: ...Notes ...

Page 55: ...r SAR Boxes and Panels TIG Torches No Labor Tregaskiss Guns No Labor Water Cooling Systems Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries 6 90 Days Parts Accessories Kits ArcReach Heater Quick Wrap and Air Cooled Cables Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls MDX Series MIG Guns M Guns MIG...

Page 56: ...personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Protective Equipment PPE Service and Repair Replacement Parts Training Schools Videos Books Welding Process Handbooks Contact the Delivering Carrier to For Service Owner s Record File a claim for loss or damage during ...

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