Miller XMT 400 CC User manual

Miller
April
1994
Form:
OM-155
152B
Effective
With
Serial
No.
KE621
826
OWNERS
MANUAL
XMTfi
400
CC

CC/DC
Welding
Power
Source

For
GTAW, GTAW-P,
And
SMAW
Welding

400
Amperes,
36
Volts
DC
At 60%
Duty
Cycle

Uses
Three-Phase
Input
Power

Protection For
Control
Circuit,
24
VAC,
And
Overheating
 14-Pin Remote Control
Receptacle

See Rear Cover
For
Options
And
Accessories

U


Read and follow these instructions and all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the directions.

Give
this
manual
to
the
operator.
~
1I~fl
U
For
help,
call
your
distributor

or:
MILLER
Electric
Mfg.
Co.,
P.O. Box
1079,
Appleton,
WI
54912
414-734-9821
cover
1/94

ST-i
52 303-A
'
1994
MILLER
Electric
Mfg.
Co.
PRINTED
IN
USA

iJ
MILLERS
TRUE BLUETM
LIMITED WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial number
preface
of KC
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
and conditions
below.
MILLER
Electric
MIg.
Co.,
Appleton,
Wisconsin,
warrants to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
after
the
effective
date
of
this
limited
warranty
is
tree
of de
facts
in
material
and
workmanship
at
the time
it
is
shipped by
MILLER. THIS
WAR
RANTY IS EXPRESSLY IN LIEU OF ALL
OTHER
WARRANTIES.
EXPRESS
OR
IMPUED,
INCLUDING
THE
WARRANTIES
OF MERCHANTABILITY AND FIT
NESS.
Within the
warranty
periods
listed
below.
MILLER
will
repair
or
replace
any
war
ranted
parts
or
components
that
fail
due
to
such
defects
in
material
or
workmanship.
MILLER
must
be
notified in
writing
within
thIrty
(30)
days
of
such
defect
or
failure,
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shall honor
warranty
claims on
warranted
equipment
listed below
in
the
event
of
auch
a
failure within
the
warranty
time
periods.
All
warranty
time
periods
atari
on
the date
that
the
equIpment
was
delivered
to
the
Original
retail
purchaser,
or
one
year
after
the
equipment
Is
sent to
the
distributor.
1.
5YearsParts3YearaLabor
*

Original
main
power
rectifiers
2.~
3YearsPartaandLabor

Transformer/Rectifier
Power
Sources

Plasma
Arc
Cutting
Power Sources
Semi-Automatic and Automatic
Wire
Feeders

Robots
3.
2
Years

Parts and
Labor

Engine
Driven
Welding
Generators
(NOTE:. Engines
are
warranted
separately
by
the
engine
manufacturer
for
a
period
of
iwo
years.)

Air
Compressors
4.
1
Year

Parts
and
Labor
Motor
Driven Guns

Process
Controllers

Water
Coolant
Systems

HFUnits

Grids

Spot
Welders
Load
Banks

SDX Transformers

Running
Gear/Trailers

Field
Options
(NOTE:
Field
options
are
covered
under
True
BIueTM
for
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
minimum
of
one
year
whichever is greater.)
5. 8
Months

Batteries
6.
90
Days

Parts and
Labor

MiG
GunalTIG
Torches

Plasma
Cutting
Torches

Remote Controls

Accessory
Kits

Replacement
Parts
MILLERS True
BlueTM
Limited
Warranty
shall
not
apply
to:
1.
Items
fumlshed
by
MILLER.
but
manufactured
by
others,
such
as
engInes
or
trade accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzlas,
contactors
and
relays
or
parts
that
fail
due
to
normal
wear.
3.
Equipment
that has
been modified
by any
party
Other than
MILLER.
or
equip
ment
that
has
been
improperly
installed,
improperly
operatod
or
misused
based
upon
industry
standards,
or
equipment
whIch
has
not
had reasonable
and
necessary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED FOR PURCHASE
AND
USE
BY
COMMER
CIAL/INDUSTRIAL USERS
AND
PERSONS TRAINED
AND
EXPERIENCED
IN
THE USE AND MAINTENANCE OF WELDING
EQUiPMENT.
In the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be,
at
MILLERS
option: (I) repair~
or
(2)
replacement;
or,
where
authorized
in
writing
by
MILLER
inappropriate
cases,
(3)
the
reasonable
Cost
of
repair
or
replace-
mental
an
authorized
MILLER
service
station;
or
(4)
payment
of
or
ci
edit for the
pur
chase
price (less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers risk
and
expense.
MILLERS
option
of
repair
or
replacement
will be
FOB.,
Factory
atAppleton.
Wisconsin,
or
F.O.B.
ala
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER. Therefore
no
compensation
or
reimburse
ment
for
transportation
costa
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTEDBY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE THE
SOLE
AND
EXCLUSIVE REMEDIES.
IN
NO EVENT
SHALL
MILLER
BE
LIABLE
FOR
DIRECT, INDIRECT, SPECIAL,
INCIDENTAL OR
CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS OF
PROFIT),
WHETHER BASED ON
CON
TRACT.
TORT OR
ANY OTHER LEGAL THEORY.
ANY
EXPRESS
WARRANTY
NOT PROVIDED HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY OR REPRESENTATION
ASTO
PERFORMANCE,
AND ANY
REMEDY
FOR
BREACH
OF CONTRACT TORT OR
ANY
OIHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT ARISE BY
IMPLICATION.
OPERATION
OF
LAW,
CUSTOM OF
TRADE OR
COURSE OF
DEALING,
IN
CLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
In the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts,
or
the exclusion
of
Incidental,
indirect,
special
or
consequential damages,
so
the above limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights,
and other
rights
may
be
available,
but
may
vary
from
state to
state.
In
Canada,
legislation
in
some
provinces provides
for certain
additional
warranties
or
remedies
other
than
as stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the lImitations and exclusions
set out
above
may
not
apply.
This
Limited
Warranty provides specific
legal
rights,
and other
rights
may
be
available,
but
may
vary
from
province
to
province.
RECEIVING-HANDLING
Before
Unpacking
equipment,
check
carton
for
any
damage
that
may
have occurred
during shipment.
File
any
claims
for loss
or
damage
with the
delivering
carrier.
Assistance for
filing
or
settling
claims
may
be
obtained
from distributor and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
Unit. The
information
is located
on
the
rating
label
or
nameplate.
Model
Serial
or
Style
No.
Date
of Purchase
miller 9/93

ERRATA
SHEET
July
19,
1994
FORM:
OM-155
152B
Use above
FORM
number when
ordering
extra
manuals.
After
this
manual
was
printed,
refinements in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
CHANGES TO
SECTION
8-
PARTS
LIST
Change
Parts List
as
follows:
Part
**
No.
Replaced
With
Description
Quantity
25-
Added
29-
152300
30-
166 250
169772
.
169402.
169 403
.
.
SPACER,
case
(Effw/KE679384)
.
HEATSINK,IGBTLH
.
HEAT
SINK,
IGBT
RH
8
1
1
**First
digit
represents
page
no

digits
following
dash
represent
item
no.
BE
SURE TO PROVIDE
MODEL AND SERIAL NUMBER
WHEN ORDERING
REPLACEMENT
PARTS.

ARC
WELDING SAFETY
PRECAUTIONS
a
WARNING
ARC
WELDING
can
be
hazardous.
PROTECT YOURSELF
AND
OTHERS
FROM POSSIBLE
SERIOUS
INJURY
OR
DEATH. KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL CONSULTING
YOUR DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below is
only
a
summary
of the
more
complete
safety
information
that
will
be found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE ALL
INSTALLATION,
OPERATION, MAINTENANCE,
AND REPAIR
WORK PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
ELECTRIC SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal shocks
or
severe
burns. The
electrode
and
work
circuit
is
electrically
live whenever
the
output
is
on. The
input
power
circuit
and
machine internal
circuits
are
also
live when
power
is
on.
In semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and all metal
parts
touchin9
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch live electrical
parts.
2.
Wear
dry,
hole-free
insulating gloves
and
body
protection.
3. Insulate
yourself
from work and
ground
using
dry
insulating
mats
or covers
big enough
to
prevent
any
physical
contact
with
the work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
poweraccording
to
OSHA
29
CFR
1910.147
(see Safety
Standards).
5.
Properly
install and
ground
this
equipment
according
to
its
Owners Manual and
national,
state,
and
local
codes.
6.
Always verify
the
supply ground

check
and
be
sure
that
input
oower
cord around wire is Drooerlv
connected
to
around
terminal
in
disconnect box
or
that cord
plug
is
connected
to
a
properly
grounded receptacle
outlet.
7. When
making input
connections,
attach
proper
grounding
conductor
first

double-check
connections.
8.
Frequently inspect
input
power
cord for
damage
or
bare
wiring

replace
cord
immediately
if
damaged

bare
wiring
can
kill.
9.
Turn
off all
equipment
when
not
in
use.
10. Do
not
use
worn,
damaged,
undersized,
or
poorly spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12. If earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable

do
not
use
work
clamp
or
work cable.
13. Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another electrode from
a
different
machine.
14.
Use
only
well-maintained
equipment. Repair
or
replace
damaged
parts
at
once.
Maintain unit
according
to
manual.
15.
Wear
a
safety
harness
if
working
above
floor
level.
16.
Keep
all
panels
and
covers
securely
in
place.
17.
Clamp
work
cable with
good
metal-to-metal
contact to
workoiece
or
worktable
as near
the
weld
as
oractical.
(/~
-
..
--
ARC RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing;
FLYING
SLAG OR SPARKS
can
injure
eyes.
Arc
rays
from the
welding
process
produce
intense
visible and invisible
(ultraviolet
and
infrared)
rays
that
can
burn
eyes
and skin. Noise from
some
processes
can
damage hearing.
Chipping, grinding,
and
welds
ARC RAYS
2.
Wear
a
welding
helmet fitted with
a
proper
shade of filter
to
protect
yourface
and
eyes
when
welding
orwatching
(see
ANSI
Z49.1 and Z87.1
listed
in
Safety Standards).
3.
Wear
approved
safety glasses
with side
shields.
4.
Use
protective
screens or
barriers
to
protect
others from
flash
cooling
throw
off
pieces
of
metal
or
slag.
and
glare;
warn
others
not to
watch the
arc.
NOISE
5. Wear
protective
clothing
made
from
durable,
flame-resistant
1.
Use
approved
ear
plugs
or ear
muffs
if
noise
level is
high.
material
(wool
and
leather)
and foot
protection.
I
FUMES
AND
GASES
can
be
hazardous
5.
Work in
a
confined
space
only
if it
is well
ventilated,
or
while
to
your
health.
I
I
Welding produces
fumes and
gases.
Breathing
these
.......J
fumes and
gases
can
be
hazardous
to
your
health,
1.
Keep
your
head
out
of
the
fumes. Do
not
breathe
the
fumes.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
6.
wearing
an
air-supplied
respirator.
Always
have
a
trained
watchperson nearby.
Welding
fumes
and
gases
can
displace
air
and lower the
oxygen
level
causing injury
or
death.
Be
sure
the
breathing
air is safe.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The heat
and
rays
of the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
remove
welding
fumes and
gases.
3.
If
ventilation
is
poor,
use an
approved
air-supplied respirator.
7,
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless
the
coating
is
removed from the
4.
Read
the
Material
Safety
Data Sheets
(MSDSs)
and the weld
area,
the
area
is well
ventilated,
and
if
necessary,
while
manufacturers
instruction
for
metals,
consumables,
coatings, wearing
an
air-supplied
respirator.
The
coatings
and
any metals
cleaners,
and
degreasers.
containing
these
elements
can
give
off
toxic fumes if
welded.
CYLINDERS
can
explode
if
damaged.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to treat
them
carefully.
5.
6.
7.
Never allow
a
welding
electrode
to
touch
any
cylinder.
Never weld
on a
pressurized cylinder

explosion
will
result.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
8. Turn face
away
from
valve outlet
when
opening cylinder
valve.
mechanical
shocks,
slag,
open
flames,
sparks.
and
arcs.
9.
Keep protective
cap
in
place
over
valve
except
when
cylinder
is
2.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
in
use or
connected
for
use.
support
or
cylinder
rack
to
prevent
falling
or
tipping.
10.
Read and follow instructions
on
compressed
gas
cylinders,
3.
Keep cylinders
away
from
any
welding
or
other electrical
associatedequipment,andCGApublicationP-1
listedinSafety
circuits.
Standards.
srl1.1
2194