Miller Electric XMT 456CV manual

OM-203 034N 2007 − 10 Processes MIG (GMA W) W elding With Optional Equipment: Pulsed MIG (GMAW -P) XMT 456 CC/CV: Multiprocess W elding Description Invision 456P: Invision 456P: XMT 456 CC/CV: R Invision 456P And X M T 4 5 6 C C / C V (400 V olt Models) R File: MIG (GMA W) V isit our website at www.MillerWelds.com[...]

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

dec_stat_6/05 Declaration of Conformity for European Community (CE) Products . This information is provided for units with CE certification (see rating label on unit). Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W . Spencer St. Managing Director Appleton, WI 54914 USA MILLER Europe S.r .l. Phone: (920) 734-982[...]

OM-203 034 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007 − 04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols[...]

OM-203 034 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poo[...]

OM-203 034 Page 3 D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards. 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 [...]

OM-203 034 Page 4 1-4. California Proposition 65 W arnings W elding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and l[...]

OM-203 034 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007 − 04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es u t ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures gra[...]

OM-203 034 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CH[...]

OM-203 034 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants m[...]

OM-203 034 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de toucher d[...]

OM-203 034 Page 9 2-5. P ri nc ipa le s no rm es d e sé cu ri té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping , American [...]

OM-203 034 Page 10[...]

OM-203 034 Page 1 1 SECTION 3 − DEFINITIONS 3-1. Manufacturer ’ s W arning Label Definitions W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring 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 yo[...]

OM-203 034 Page 12 > 60 s V S-179 190-A V V 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on machine. 4 Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. 5 Always wait 6[...]

OM-203 034 Page 13 3-2. Symbols And Definitions A Amperage Panel Alternating Current (AC) V V oltage Output Circuit Breaker Remote On Of f Gas Tungsten Arc W elding Negative V oltage Input Direct Current (DC) Positive Inductance Protective Earth (Ground) Constant Current Constant V oltage Foot Control Line Connection Arc Force Shielded Metal Arc W [...]

OM-203 034 Page 14 3-4. Manufacturer ’ s Rating Labels 217 204-C / 223 527-B . CV Model . CC/CV Model[...]

OM-203 034 Page 15 SECTION 4 − INST ALLA TION . This manual contains information on CC and CC/CV units. Differences between models are noted throughout this manual. 4-1. Specifications Input Power Rated W elding Output Amperage Range V oltage Range Maximum Open- Circuit Amperes Input At Rated Load Output 50 Hz, Three-Phase P ower O u t pu t R ang[...]

OM-203 034 Page 16 4-3. V olt-Ampere Curves V olt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. va_curve1 4/95 − SA-181 561 / SA-181 562 CC Modes CV Modes 4-4. Dimensions And Weight Hole Layout Dimensions A F A 14-21/64 in (363.9 mm) A B 20-3/4 in ([...]

OM-203 034 Page 17 4-5. Selecting A Location loc_2 3/96 - 800 61 1 / 802 260 1 Lifting Forks Use lifting forks to move unit. 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 Rating Label Use rating label to determine input power needs. 5 Line Disconnect Dev[...]

OM-203 034 Page 18 4-7. W eld Output T erminals And Selecting Cable Sizes ! 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 weldin[...]

OM-203 034 Page 19 4-8. Connecting Weld Output Cables 803 778-B ! T urn off power before connecting to weld output terminals. ! Failure to properly connect weld cables may cause excessive heat an d start a fire, or damage your ma- chine. 1 Weld Output T erminal 2 Supplied Weld Output T erminal Nut 3 Weld Cable T erminal 4 Copper Bar Remove supplied[...]

OM-203 034 Page 20 4-10. 1 15 V olts AC Duplex Receptacle Ref. 801 524-A 1 1 15 V 7 A AC Receptacle Power is shared between duplex receptacle and Remote 14 recep- tacle (see Section 4-9). 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB 1 protects 1 15 volts ac portion of duplex receptacle and Remote 14 receptacle from overload. CB2 protects 24 volts[...]

OM-203 034 Page 21 4-12. Connecting Input Power ssb2.4* 1/94 − 801 523-B / 801 946 T ools Needed: 5/16 in Input Filter Board L1 =GND/PE ! T urn Off welding power source, and check voltage on input capacitors according to Section 6-3 before pro- ceeding. Check input voltage available at site. Remove left side panel. 1 Input And Grounding Conductor[...]

OM-203 034 Page 22 SECTION 5 − OPERA TION 5-1. Front Panel Controls For CV Only Models 1 Power On/Off Switch . The fan motor is thermostatically controlled and only runs when cooling is needed. 2 V oltmeter (see Section 5- 3 ) 3 Ammeter (see Section 5-3) 4 V oltage Adjustment Control 5 Inductance Control Inductance determines the “wetness” of[...]

OM-203 034 Page 23 5-3. Meter Functions For CV Only Models . The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle Meter Reading While W elding MIG Preset V olts Blank VA 24.5 Actual V olts Actual Amps VA 24.5 250 Pulsed MIG Pulse Display Pulse Display VA PPP PPP Actual [...]

OM-203 034 Page 24 5-5. Meter Functions For CC/CV Models . The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle Panel Control (GT AW) Actual V olts (OCV) Preset Amps VA 80.0 85 Lift-Arc T rigger Hold TIG (GT AW) VA Blank Preset Amps 85 TIG (GT AW) Blank Preset Amps VA 8[...]

OM-203 034 Page 25 5-6. Mode Switch Settings For CC/CV Models . Th e SMA W modes provide the Adaptive Hot Start ™ feature, which automatically increases the output amperage at the start of a weld should the start require it. This eliminates electrode sticking at arc start. Mode Output Control Scratch Start TIG (GT AW) Select: or Amp W eld: Lift-A[...]

OM-203 034 Page 26 5-7. Lift-Arc TIG Procedure For CC/CV Models With Mode switch in the Lift-Arc TIG position, start an arc as follows: 1 TIG Electrode 2 W orkpiece T ouch tungsten electrode to work- piece at weld start point, hold electrode to workpiece for 1-2 seconds , and slowly lift electrode. An arc will form when electrode is lifted. Normal [...]

OM-203 034 Page 27 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace Damaged Or Unreadable Labels Replace Cracked T orch Body Repair Or Replace Cracked Cables Repair Or Replace Cracked Cables And Cords Clean And T ighten W [...]

OM-203 034 Page 28 6-3. Removing Case and Measuring Input Capacitor V oltage Turn Of f welding power source, a nd disconnect input power . 1 Outside Handle Screws T o loosen top, remove two outside handle screws from both handles and all side bolts. 2 Interconnecting Board PC2 3 V oltmeter Measure the dc voltage across th e screw terminals on RC3 a[...]

OM-203 034 Page 29 6-4. V oltmeter/Ammeter Help Displays . Al l directions are in reference to th e front of the unit. All circuitry referred to is located inside the unit. 1 Help 0 Display Indicates a shorted thermistor R T2 on the left side of the unit. If this dis- play is shown, contact a Factory Authorized Service Agent. 2 Help 1 Display Indic[...]

OM-203 034 Page 30 6-5. T roubleshooting T rouble Remedy No weld output; unit completely inop- erative. Place line disconnect switch in On position (see Section 4-12 ). Check and replace line fuse(s), if necessary , or reset circuit breaker (see Section 4-12 ). Check for proper input power connections (see Section 4-12 ). No weld output; meter disp[...]

OM-203 034 Page 31 Notes[...]

OM-203 034 Page 32 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram For CV Only Welding Power Source[...]

OM-203 034 Page 33 203 505-A[...]

OM-203 034 Page 34 Figure 7-2. Circuit Diagram For CC/CV Welding Power Source[...]

OM-203 034 Page 35 204 950 − B[...]

OM-203 034 Page 36 SECTION 8 − P ARTS LIST . Hardware is common and not available unless listed. 802 261-E 68 67 57 56 55 52 10 61 60 47 43 36 38 37 36 35 34 30 8 7 6 5 4 66 3 PC2 PC1 4 65 64 63 62 59 58 54 53 51 46 50 49 48 46 45 44 4 42 41 40 39 33 32 31 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 9 2 1 Figure 8-1. Complete Assembl[...]

OM-203 034 Page 37 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Complete Assembly Quantity 1 187 234 Cover , T op 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 195 585 Handle 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-203 034 Page 38 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Complete Assembly (Continued) Quantity 48 180 732 Boot, Neg Output Stud 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 179 848 Boot, Pos Output Stud 1 . . . . . . . . . . . . . . . . . . . . . .[...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe[...]

PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 9 20-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters −[...]