Instruction/ maintenance manual of the product XMS 4000 Miller Electric
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Processes Multiprocess W elding OM-224 043B 2006 − 07 Description Arc W elding Power Source XMS 4000 400 V olts R.
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 .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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).
OM-224 043 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.
OM-224 043 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
OM-224 043 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.
OM-224 043 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 .
OM-224 043 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.
OM-224 043 Page 6 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.
OM-224 043 Page 7 207 290 = 100 h. std. 2 1 3 5 4 7 6 1 Warning! 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.
OM-224 043 Page 8 2-2. Manufacturer ’ s Rating Labels 2-3. Symbols And Definitions A Amperage V V oltage Alternating Current (AC) Hz Hertz Remote On Of f Protective Earth (Ground) Line connection Th.
OM-224 043 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.
OM-224 043 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.
OM-224 043 Page 1 1 3-5. Selecting A Location 1 Lifting Handles Do not use handle to lift unit. 2 Rating Label Use label to determine input power needs.
OM-224 043 Page 12 3-6. 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 .
OM-224 043 Page 13 3-8. 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.
OM-224 043 Page 14 3-10. 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.
OM-224 043 Page 15 SECTION 4 − OPERA TION 4-1. Front Panel Controls 6 7 21 4 3 1 ON/OFF Switch (I/O) Use switch to turn unit On/Off. . Fan is thermostatically controlled and runs only when necessary (Fan On Demand). . W ater cooling is automatically con- trolled and runs only when necessary .
OM-224 043 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 .
OM-224 043 Page 17 4-4. Wire T ype Selection in Synergic MIG or Synergic Pulsed MIG W elding L5 LED L6 LED L7 LED L8 LED 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 .
OM-224 043 Page 18 4-6. Gas Selection in Synergic MIG or Synergic Pulsed MIG Welding L13 LED L14 LED L15 LED L16 LED P6 Push Button Press P 6 until gas LED illuminates. D1 and D2 will show gas name momentarily and then it will return to the main display .
OM-224 043 Page 19 4-8. Setting And Using W eld Parameters From Memory (TIG and STICK Only) . 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.
OM-224 043 Page 20 4-10. 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 the proper cable bundle, connect unit to the wire feeder (see Wire Feeder manual).
OM-224 043 Page 21 4-12. Selecting Synergic MIG W elding Set Synergic MIG welding process using P3 push button. In Synergic MIG mode, the operator may need to adjust welding data (wire type, wire diameter , and gas type) and only one weld parameter .
OM-224 043 Page 22 4-13. Selecting Synergic Pulsed MIG W elding P3 P6 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.
OM-224 043 Page 23 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 3 and the gas pipe to the gas connector 5. Using a cable with a proper adapter , con- nect work clamp cable to the MIG gun con- nector .
OM-224 043 Page 24 4-15. 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.
OM-224 043 Page 25 SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions.
OM-224 043 Page 26 5-2. Blowing Out Inside Of Unit Y Do not remove case when blowing out inside of unit. T o blow out unit, direct airflow through front, side, and back louvers as shown. 5-3. Help Displays . Al l directions are in reference to the front of the unit.
OM-224 043 Page 27 5-4. T roubleshooting T rouble Remedy No weld output: unit completely inopera- tive Place line disconnect switch in On position (see Section 3-10 ). ti ve. Check and replace line fuse(s), if necessary , or reset circuit breaker (see Section 3-10 ).
OM-224 043 Page 28 Notes.
OM-224 043 Page 29 SECTION 6 − ELECTRICAL DIAGRAM May 9, 2005.
OM-224 043 Page 30 SECTION 7 − P ARTS LIST . Hardware is common and not available unless listed. May 1 1, 2005 Figure 7-1. Unit Outer Assembly.
OM-224 043 Page 31 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Unit Outer Assembly Quantity 1 V57038158 T urntable 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-224 043 Page 32 . Hardware is common and not available unless listed. May 1 1, 2005 Figure 7-2. Unit Main Assembly.
OM-224 043 Page 33 Description Part No. Dia. Mkgs. Item No. Figure 7-2. Unit Main Assembly Quantity 20 CR5,6,R1 000175940 Resistor/Capacitors 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 000199840 Bus bar , diode 2 .
Notes.
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.
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.
An important point after buying a device Miller Electric XMS 4000 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric XMS 4000 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric XMS 4000 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric XMS 4000 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric XMS 4000 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric XMS 4000, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric XMS 4000.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric XMS 4000. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric XMS 4000 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
