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Miller XMT 450 CC User Manual

Miller XMT 450 CC
84 pages
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Arc Welding Power Source
XMT 450 CC/CV
TM-257 220B 2015−03
Eff w/Serial Number MC100104A
Processes
Description
Multiprocess Welding
File: MULTIPROCESS
Visit our website at
www.MillerWelds.com
R
(400 Volt Model)
CE

Table of Contents

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Miller XMT 450 CC Specifications

General IconGeneral
BrandMiller
ModelXMT 450 CC
CategoryWelding System
LanguageEnglish

Summary

Safety Precautions for Servicing

Symbol Usage and Warnings

Explains danger, warning, and notice symbols used in the manual.

Servicing Hazards and Precautions

Details hazards like electric shock, moving parts, hot parts, and falling equipment.

California Proposition 65 Warnings

States product contains chemicals known to cause cancer and reproductive harm.

Electromagnetic Fields (EMF) Information

Discusses EMF effects, protective measures, and user responsibility for interference.

Definitions and Safety Symbols

Additional Safety Symbols and Definitions

Explains symbols for WEEE, gloves, insulation, power disconnect, fumes, flammables, sparks.

Miscellaneous Symbols and Definitions

Defines symbols for amperage, voltage, current, frequency, etc.

Technical Specifications

Features and Benefits

Describes features like LVCT, Wind Tunnel Technology, Fan-On-Demand, Auto Remote Sense, Lift-Arc, Adaptive Hot Start.

Arc Control Features

Explains DIG and Inductance controls for arc characteristics.

Serial Number and Rating Label Location

States the location of serial number and rating label for product identification.

Unit Specifications Table

Provides a table of input power, output, amperage, voltage, KVA, and KW ratings.

Dimensions and Weight

Lists hole layout dimensions, overall dimensions, and weight of the unit.

Environmental and Compatibility Specifications

Details IP rating, EMF information, and EMC compliance.

Duty Cycle and Overheating

Explains duty cycle, effects of overheating, and related warnings.

Volt-Ampere Curves

Shows minimum and maximum voltage/amperage output capabilities for CC and CV modes.

Installation Procedures

Selecting a Location for Installation

Provides guidelines for choosing an installation location, including movement and tipping precautions.

Weld Output Terminals and Cable Sizing

Details how to select appropriate weld cable sizes based on amperage and cable length.

Connecting Weld Output Cables

Illustrates correct and incorrect installation of weld output cables.

Remote 14 Receptacle Information

Explains the function of each pin in the 14-pin remote receptacle.

115V AC Receptacle and Protectors

Identifies the 115V AC receptacle and its associated protective circuit breakers.

Shielding Gas Connection and Operation

Details how to connect shielding gas and explains gas solenoid operation for TIG processes.

Electrical Service Guide

Provides recommendations for input voltage, amperage, fuses, and conductor sizing.

Connecting Input Power

Illustrates the wiring diagram and steps for connecting the main input power.

General Operation

Front Panel Controls and Displays

Identifies and describes the function of each control and display on the front panel.

Mode Switch Settings

Details the switch positions, corresponding processes, and output/panel adjustments.

GTAW (TIG) Operation

GTAW Process Connection Diagram

Shows the typical setup for Gas Tungsten Arc Welding (GTAW).

Scratch Start TIG Welding Mode

Explains how to set up and operate the Scratch Start TIG welding mode.

Lift-Arc TIG Welding Mode

Details the setup and operation of the Lift-Arc TIG welding mode.

Remote Scratch Start TIG Welding Mode

Explains operating Scratch Start TIG with a remote control.

GMAW/FCAW Operation

GMAW/FCAW Remote Feeder Connection

Shows the setup for Gas Metal Arc Welding/Flux Cored Arc Welding with a remote feeder.

MIG Welding Mode Operation

Explains how to set up and operate the MIG welding mode, including Arc Control.

GMAW-P Remote Feeder Connection

Shows the setup for Pulsed Gas Metal Arc Welding with a remote feeder and pulsing device.

Pulsed MIG Welding Mode Operation

Explains operating the Pulsed MIG welding mode, noting the requirement for an external pulsing device.

V-Sense Feeder GMAW/FCAW Connection

Shows the connection diagram for a Voltage-Sensing Feeder setup.

V-Sense Feeder Welding Mode Operation

Explains how to set up and operate the V-Sense Feeder welding mode.

SMAW/CAC-A Operation

SMAW/CAC-A Process Connection Diagram

Shows the typical setup for Shielded Metal Arc Welding and Air Carbon Arc cutting.

Remote Stick Welding Mode Operation

Explains operating Stick welding with a remote control, including Adaptive Hot Start and Arc Control.

Stick Welding Mode Operation

Details setting up and operating Stick welding, including Adaptive Hot Start and Arc Control (Dig).

Optional Low OCV Welding Modes

Describes the optional low OCV configuration for Stick and Scratch Start TIG modes.

Alternate Configuration Functions

Explains three ways to configure remote control operation and meter display.

Theory of Operation

Block Diagram of Operation

Presents a block diagram illustrating the major components and signal flow.

Troubleshooting Guide

Pre-Power Checks

Outlines essential checks to perform before applying power to avoid further damage.

Measuring Input Capacitor Voltage

Details how to safely remove the case and measure input capacitor voltage.

Input Rectifier (SR1) Testing

Describes visual inspection and diode testing procedures for the input rectifier module.

IGBT Modules (PM1, PM2) Testing

Explains how to test IGBT modules using a tester or DMM.

Interconnect Board (PC2) Testing

Details testing procedures for diodes, resistors, and capacitors on the interconnect board.

Output Diodes (D1-D4) Testing

Describes visual inspection and diode testing for output diodes.

Input Contactor (W1) Testing

Explains how to verify the contacts and coil resistance of the input contactor.

Tank Capacitors (C1, C2) Testing

Describes how to check tank capacitors for shorts and capacitance.

Comprehensive Troubleshooting Table

Lists common troubles and their remedies, guiding users through diagnostics.

Help Codes and Error Messages

Explains the meaning of help codes displayed by the unit and their potential causes/solutions.

Troubleshooting Circuit Diagram

Provides the main circuit diagram for troubleshooting purposes.

Troubleshooting Circuit Readings

Lists expected resistance and voltage readings for various points in the circuit diagram.

Inverter Control Board (PC1) Testing

Details testing procedures and test points for the Inverter Control Board PC1.

Inverter Control Board (PC1) Test Point Values

Lists specific voltage readings for various pins on the Inverter Control Board PC1.

PC1 Diagnostic LEDs

Explains the function of diagnostic LEDs on the Inverter Control Board PC1.

Interconnect Board (PC2) Testing

Provides information for testing the Interconnect Board PC2.

Interconnect Board (PC2) Test Point Values

Lists specific voltage readings for various pins on the Interconnect Board PC2.

Front Panel/Display Board (PC3) Testing

Details testing procedures for the Front Panel/Display Board PC3.

Front Panel/Display Board (PC3) Test Point Values

Lists specific voltage readings for various pins on the Front Panel/Display Board PC3.

Checking Unit Output After Servicing

Describes how to check the unit's output after servicing is completed.

Enabling Low OCV Welding Modes

Details the procedure to enable optional low OCV welding modes.

Checking Bus Voltage Imbalance

Explains how to check for bus voltage imbalance, especially after component replacement.

Maintenance Procedures

Routine Maintenance Schedule

Outlines maintenance tasks to be performed at 3-month and 6-month intervals.

Cleaning the Inside of the Unit

Describes how to safely blow out dust and debris from the unit's interior.

Electrical Diagrams

400 Volt Model Circuit Diagram

Provides the detailed circuit diagram for 400 Volt models.

Wiring Diagram (Part 1 of 2)

Shows the wiring diagram for 400 Volt models, part one.

Wiring Diagram (Part 2 of 2)

Shows the wiring diagram for 400 Volt models, part two.

Parts List

Parts Assembly Diagram

Illustrates the assembly of various parts of the welding unit.

Detailed Parts List

Provides a detailed list of part numbers, descriptions, and quantities.

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