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Miller Electric XMC 4000 manual

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Table of contents for the manual

  • Page 1

    Processes Multiprocess W elding OM-221 694B 2006 − 07 Description Arc W elding Power Source XMC 4000 400 V olts R[...]

  • Page 2

    Thank you and congratulations on choosing Miller . Now you can get the job done and get it done right. W e 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 . Like you, his customers couldn’t af [...]

  • Page 3

    INDICE SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . . . . [...]

  • Page 4

    dec_stat_Milan_6/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: ITW Welding Products Italy S.r .l. Mr . Danilo Fedolfi, Via Privata Iseo 6/E Managing Director 20098 San Giuliano ITW Welding Products Italy[...]

  • Page 5

    OM-221 694 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety me[...]

  • Page 6

    OM-221 694 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching[...]

  • Page 7

    OM-221 694 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.[...]

  • Page 8

    OM-221 694 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American W elding Society Standard A [...]

  • Page 9

    OM-221 694 Page 5 SECTION 2 − DEFINITIONS 2-1. Manufacturer ’ s W arning Label Definitions W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric shock by insul[...]

  • Page 10

    OM-221 694 Page 6 A W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from wiring can kill. 2 Disconnect input plug or power before working on machine. 3 Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. 4 Always wait 60 seconds after power is turn[...]

  • Page 11

    OM-221 694 Page 7 207 290 = 100 h. std. 2 1 3 5 4 7 6 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Disconnect input plug or power before working on machine. 3 W ear approved safety glasses with side shields while working on the unit. 4 Plugged filter or hoses can cause overheating to the power source and torch. 5 Ev[...]

  • Page 12

    OM-221 694 Page 8 2-2. Manufacturer ’ s Rating Labels 2-3. Symbols And Definitions A Amperage Alternating Current (AC) V V oltage Remote On Of f Protective Earth (Ground) Line connection Three Phase Direct Current (DC) Constant V oltage Gas Tungsten Arc W elding Lift-Arc Operation (GT AW) Constant Current Inductance Increase Three Phase Static Fr[...]

  • Page 13

    OM-221 694 Page 9 SECTION 3 − INST ALLA TION 3-1. Specifications Rated W elding Output V oltage Range Amperage Range Maximum Open-Circuit V oltage DC IP Rating Amperes Input at Rated Load Output 50/60 Hz Output Range Range V o l tage DC 400 V KV A KW 300 A @ 32 V olts DC, 60% Duty Cycle 10 − 35 5 − 400 90 23C 17.0 (0,15*) 12.4 (0,09*) 1 1.5 ([...]

  • Page 14

    OM-221 694 Page 10 3-3. V olt-Ampere Curves va_curve1 4/95 − SA-178 652 / SA-178 653 V olt-ampere curves show minimum and maximum voltage and amper- age output capabilities of unit. Curves of other settings fall be- tween curves shown. A. CC Mode B. CV Mode ARC CONTROL[...]

  • Page 15

    OM-221 694 Page 1 1 3-4. Selecting A Location loc_2 3/96 - ST -801 192 1 Lifting Handles Do not use handle to lift unit. 2 Rating Label Use label to determine input 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 Art[...]

  • Page 16

    OM-221 694 Page 12 3-5. W eld Output T erminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. T o reduce possible interference, keep weld cables as short as possible, close together , and down low , such as on the floor . Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this weld[...]

  • Page 17

    OM-221 694 Page 13 3-7. Circuit Breakers Circuit breakers with numbers 7 an d 10 are placed inside the welder on the wire feeder side as shown. 1 Circuit Breaker 7 Protects the auxiliary 1 15 volt AC used for the water cooling unit in- side the power source, from over- load. 2 Circuit Breaker 10 Protects the auxiliary 24 volt AC used for the wire f[...]

  • Page 18

    OM-221 694 Page 14 3-9. Electrical Service Guide Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not be available. NOTE 50/60 Hz Three Phase Input V oltage 400 Input Amperes At Rated Output 17 Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay [...]

  • Page 19

    OM-221 694 Page 15 SECTION 4 − OPERA TION 4-1. Front Panel Controls 14 20 18 19 12 10 9 11 7 8 5 6 17 13 16 15 2 1 4 3 1 ON/OFF Switch (I/O) Use switch to turn unit On/Off. 2 MIG Gun Connector Positive gun connection for MIG or elec- trode holder for Stick Electrode Positive welding process, or work clamp connec- tion for TIG welding process. 3 W[...]

  • Page 20

    OM-221 694 Page 16 4-2. Switching On the Unit and Recalling Factory Parameters . Write down any parameters that need to be restored before performing this procedure. 1 Power Switch Use power switch to turn unit On. When ITW appears on D1 and D2, press P3 and P8 simultaneously . When MEMO CLEAR appears on D1 and D2, release P3 and P8. W ait until DO[...]

  • Page 21

    OM-221 694 Page 17 4-4. Wire T ype Selection In Synergic MIG Or Synergic Pulsed MIG Welding 1 L5 LED 2 L6 LED 3 L7 LED 4 L8 LED 5 P4 Push Button Press P4 until desired material LED illumi- nates. D1 and D2 will show material name only momentarily , and then return to the main display . . D1 and D2 will show NO PROG or a selection will not be allowe[...]

  • Page 22

    OM-221 694 Page 18 4-6. T rigger Mode Selection . Always check and set a trigger mode. If trigger mode is undefined for a weld- ing process, select the desired mode. 1 L13 LED 2 L14 LED 3 L15LED 4 L16 LED 5 P6 Push Button T rigger mode can be set for TIG, Manual MIG, Synergic MIG, and Synergic Pulsed MIG welding to change when weld output power is [...]

  • Page 23

    OM-221 694 Page 19 4-7. Inductance, Material Thickness, And Gas Selection In Manual MIG, Synergic MIG, And Synergic Pulsed MIG . Incorrect settings in any process can result in a program with undesirable weld characteristics. Settings should only be changed by operators familiar with various welding processes and parameters. 1 L17 LED 2 L18 LED 3 L[...]

  • Page 24

    OM-221 694 Page 20 4-9. Setting And Using W eld Parameters From Memory . Check memory parameter for proper settings before the selections. Four memory selections are avail- able for each welding process (20 total). These memory selections provide quick changes to welding pro- cesses with preset parameter val- ues. All memory selections have factory[...]

  • Page 25

    OM-221 694 Page 21 4-1 1. Preparing Unit For MIG Welding T o select MIG welding process, proceed as follows: Follow safety precautions according to Section 1. Prepare unit according Section 3. Using a cable with a proper adapter , con- nect gun to the MIG gun connector . Connect work clamp cable to the WORK connector . If using a water-cooled gun, [...]

  • Page 26

    OM-221 694 Page 22 4-13. Manual MIG W elding Advanced Settings T o change all values list, unit must be MENU FULL. T o set unit to MENU FULL, proceed as follows: Press P2 to enter SET UP menu. Select MENU FULL on D1 and D2 (see Section 4-10 ). Wire Feed Speed Unit (only in MENU FULL) Use E1 to change D1 to UNIT . D2 value is default setting of mpm [...]

  • Page 27

    OM-221 694 Page 23 4-15. Synergic MIG Welding Advanced Settings T o change all values list, unit must be MENU FULL. T o set unit to MENU FULL, proceed as follows: Press P2 to enter SET UP menu. Select MENU FULL on D1 and D2 (see Section 4-10 ). Wire Feed Speed Unit (only in MENU FULL) Use E1 to change D1 to UNIT . D2 value is default setting of mpm[...]

  • Page 28

    OM-221 694 Page 24 4-16. Preparing Unit For Synergic Pulsed MIG Welding P3 P6 P7 E1 D1 D2 E2 P4 P5 Set Synergic Pulsed MIG welding process using P3 push button. Synergic Pulsed MIG welding is a high quality welding process that produces very little spatter . This process works well on thin metals such as stainless steel and alu- minum. In Synergic [...]

  • Page 29

    OM-221 694 Page 25 4-17. Synergic Pulsed MIG Welding Advanced Settings T o change all values list, unit must be MENU FULL. T o set unit to MENU FULL, proceed as follows: Press P2 to enter SET UP menu. Select MENU FULL on D1 and D2 (see Section 4-10 ). Wire Feed Speed Unit (only in MENU FULL) Use E1 to change D1 to UNIT . D2 value is default setting[...]

  • Page 30

    OM-221 694 Page 26 4-18. Preparing Unit For TIG Welding 4 5 6 2 1 3 P6 P3 T o select TIG welding process, proceed as follows: Follow safety precautions according to Section 1. Prepare unit according Section 3. Connect torch to the WORK connector . Using a cable with a proper adapter , con- nect work clamp cable to the MIG gun con- nector . If using[...]

  • Page 31

    OM-221 694 Page 27 4-20. TIG Lift-Arc Welding 1 1 − 2 Seconds “T ouch” Do NOT Strike Like A Match! 2 Ref. S-156 279 Lift-Arc Start When Lift-Arc t button light is On, start arc as follows: 1 TIG Electrode 2 W orkpiece T ouch tungsten electrode to work- piece at weld start point, enable out- put and shielding gas with torch trig- ger , foot co[...]

  • Page 32

    OM-221 694 Page 28 SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace Damaged Or Unreadable Labels Clean And T ighten W eld T erminals Replace Damaged Gas Hose Repair Or Replace Cracked Cables And Cords 6 Months Clean Drive [...]

  • Page 33

    OM-221 694 Page 29 5-3. Circuit Breakers CB7 And CB10 1 Circuit Breaker CB7 Protects 1 15 volts ac 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 stops. If either circuit breaker opens, allow [...]

  • Page 34

    OM-221 694 Page 30 5-4. T roubleshooting T rouble Remedy No weld output: unit completely inopera- tive Place line disconnect switch in On position (see Section 3-9 ). ti ve. Check and replace line fuse(s), if necessary , or reset circuit breaker (see Section 3-9). Check for proper input power connections (see Section 3-9 ). No weld output; meter di[...]

  • 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

    OM-221 694 Page 32 SC-187 212-A . Al l directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Help 0 Indicates sho r ted thermistor R T 2 on left side of unit. Contact a Factory Authorized Ser- vice Agent. Help 1 Indicates a malfunction in the primary power circuit. Contact a Factory Authorized S[...]

  • Page 37

    OM-221 694 Page 33 SECTION 6 − ELECTRICAL DIAGRAM January 26, 2005[...]

  • Page 38

    OM-221 694 Page 34 SECTION 7 − P ARTS LIST . Hardware is common and not available unless listed. 10 11 12 13 14 15 16 17 February 1 1, 2005 Figure 8-1. Unit Outer Assembly[...]

  • Page 39

    OM-221 694 Page 35 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Unit Outer Assembly Quantity 1 000151 187 Latch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 V16122015 Side panel 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 40

    OM-221 694 Page 36 . Hardware is common and not available unless listed. February 1 1, 2005 Figure 8-2. Unit Main Assembly[...]

  • Page 41

    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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 42

    Notes[...]

  • Page 43

    Effective January 1, 2006 This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED W ARRANTY − Subject to the terms and conditions below , ITW W elding Products Italy S.r.l., warrants to its original retail purchaser that new Miller equipment sold after t[...]

  • Page 44

    PRINTED IN USA © 2006 Miller Electric Mfg. Co. 1/06 I TW W elding Products Italy S.r . l. Via Privata Iseo, 6/E 20098 San Giuliano Milanese, Italy Phone: 39 (0) 2982901 Fax: 39 (0) 298290-203 email: miller@itw − welding.it Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address [...]