®
XMT Series
Quick
Specs
Issued August 2002 • Index No. DC/18.8
Multiprocess Welding
Power Source
Heavy Industrial Applications
Processes
Construction
Shipbuilding
Railroad
Truck and Trailer Manufacturing
Fabrication
Repair Shops
Rental Fleets
MIG (GMAW)/Pulsed MIG (GMAW-P)*
Stick (SMAW)
TIG (GTAW)/Pulsed TIG (GTAW-P)*
Flux Cored (FCAW)
Air Carbon Arc (CAC-A)
Cutting and Gouging
The Power of Blue .
304: Requires 3- or 1-Phase Power
456: Requires 3-Phase Power
Output Power Range
Weight
*With Optional Controls Only
®
Wind Tunnel Technology™ protects
electrical components and PC boards
from contamination.
Input Power
New!
304: 10 – 35 V, 5 – 400 A (3-Phase)
10 – 35 V, 5 – 400 A (1-Phase)
456: 10 – 38 V, 5 – 600 A (3-Phase)
304: Net: 76 lb (34.5 kg) Ship: 85 lb (38.6 kg)
456: Net: 118 lb (53.5 kg) Ship: 129 lb (58.5 kg)
XMT 304 MIGRunner™ power-efficient package
comes complete in one box. See page 7 for details.
Inverter arc control technology provides greater puddle
control for superior 6010 Stick electrode performance.
Line voltage compensation keeps
power constant even if power input
varies by ±10%.
Fan-On-Demand™ cooling system
operates only when needed, reducing
noise, energy use and the amount of
contaminants pulled through machine.
Process selector switch
reduces the number of
control setup combinations without reducing
any features.
Lift-Arc™ allows TIG starting without
the use of high-frequency. Starts the
arc without contaminating the weld
with tungsten.
Large, dual digital
meters are easy to view
and are presettable to
ease setting weld output.
Adaptive Hot Start™ increases the
output amperage at the start of a
weld if necessary, eliminating
electrode sticking.
XMT 304
XMT 456 CC/CV only
Primary voltage display shows what
primary voltage the power source is
set for without removing the side
panels. Saves time and assures you
that the power source has been
correctly set for available input voltage.
Unique case design helps protect
internal components from dirt and dust.
To connect input power cord and/or
set unit up for correct input power,
remove the easy-to-handle panel
(1/3 case). The remaining two-thirds of
the case never needs to be removed!
XMT 456 CC/CV
Lightweight, aerospace-grade aluminum case offers
protection with the benefit of reduced weight.
115 VAC auxiliary power (optional on XMT 304) provides
10 amps of circuit-breaker-protected power for water
circulators, etc.
Pulsed MIG capabilities
with optional Optima
control reduces spatter
and distortion, allows
better out-of-position
puddle control, and
provides potential
reduction of fume
particle emission.
XMT 304 only
Auto-Link® circuit automatically links
the power source to primary voltage
being applied (230/460 or 460/575 VAC,
single- or three-phase).
Ultra-tough, polycarbonate-blended
cover for control panel protects front
controls from damage.
International-style weld disconnects
provide high-quality weld cable
connections. (Two connectors supplied
with each unit.)
Optional remote on/off provides
ability to turn power source on or off
when it is located away from your work.
Power source is warranted for 3 years, parts and labor.
Original main power rectified parts are warranted for 5 years.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
XMT 304 Specifications
®
(Subject to change without notice.)
or
Model
Input
Power
Rated Output
at 60%
Duty Cycle
Voltage
Range in
CV Mode
Amperage
Range in
CC Mode
Max. OpenCircuit
Voltage
Amps Input at Rated Load Output, 60 Hz,
208 V 230 V 400 V 460 V 575 V KVA KW
XMT
304 CC
ThreePhase
300 A at
32 VDC
—
5 –400 A
90 VDC
33.7
30.5
17
18.9
15.2
12.2 11.6
SinglePhase
225 A at
29 VDC
—
5 –400 A
90 VDC
52.4
47.4
–
24.5
–
11.3 7.6
ThreePhase
300 A at
32 VDC
10 – 35 V
5 –400 A
90 VDC
33.7
30.5
17
18.9
15.2
12.2 11.6
SinglePhase
225 A at
29 VDC
10 – 35 V
5 –400 A
90 VDC
52.4
47.4
–
24.5
–
11.3 7.6
XMT
304
CC/CV
Certified by Canadian Standards Association and
Dimensions
Weight
H: 17 in
(432 mm)
W: 12-1/2 in
(318 mm)
D: 24 in
(610 mm)
Net: 76 lb
(34.5 kg)
Ship: 85 lb
(38.6 kg)
Listed by Underwriters’ Laboratories.
XMT 304 Control Panels
®
5
1
6
2
3
7
5
1
6
2
3
7
4
4
XMT 304 CC Model
1. Voltmeter
2. Power On/Off Switch
3. Dig Control
4. Process Selector Switch (Rotary Switch)
5. Ammeter
6. Amperage Adjustment Control
7. Amperage Control Switch
XMT 304 CC/CV Model
1. Voltmeter
2. Power On/Off Switch
3. Inductance/Dig Control
4. Process Selector Switch (Rotary Switch)
5. Ammeter
6. Voltage/Amperage Adjustment Control
7. Voltage/Amperage Control Switch
XMT 304 Performance Data
®
100
100
500
90
90
400
80
80
70
70
300
SINGLE-PHASE
200
60
MAX.
50
40
SMAW/GTAW MIN.
30
150
ARC CONTROL
10
15
20
25 30
40
% DUTY CYCLE
50
60 70 80 90 100
50
MAX.
40
30
20
10
60
VOLTS
THREE-PHASE
VOLTS
WELDING AMPERES
600
100
0
2
CV VOLT/AMP CURVE
(CC/CV Model only)
CC VOLT/AMP CURVE
DUTY CYCLE CHART
100%
0
20
0
0
50 100 150 200 250 300 350 400 450
AMPS
MIN.
10
0
50 100 150 200 250 300 350 400 450
AMPS
XMT 456 CC/CV Specifications
®
Input
Power
Rated Output
ThreePhase
450 A at 38 VDC,
100% Duty Cycle
(Subject to change without notice.)
Voltage
Range in
CV Mode
Amperage
Range in
CC Mode
Max. OpenCircuit
Voltage
Amps Input at Rated Load Output, 60 Hz
230 V 400 V 460 V 575 V KVA KW
10 – 38 V
5 –600 A
95 VDC
50.8
31
27.8
24.4
21.2 19.2
565 A at 43 VDC,
60% Duty Cycle
Dimensions
Weight
H: 17 in (432 mm)
W: 14-1/2 in (368 mm)
D: 26 in (660 mm)
Net: 118 lb
(53.5 kg)
Ship: 129 lb
(58.5 kg)
XMT 456 CC/CV Control Panel
®
1. Voltmeter
2. Power On/Off Switch
3. Arc Control
4. Ammeter
5. Voltage/Amperage Adjustment Control
6. Voltage/Amperage Control Switch
7. Process Selector Switch (Rotary Switch)
4
1
5
2
6
3
7
XMT 456 CC/CV Performance Data
®
DUTY CYCLE CHART
600
CV VOLT/AMP CURVES
100
500
60
40
MAX.
200
20
MIN.
150
0
0
100
200
300
400
500
600
700
600
700
AMPERAGE
100
0
10
15
20
25
30
40
50
60
70 80 90 100
% DUTY CYCLE
CC VOLT/AMP CURVES
100
SMAW-MAX
80
Volt/amp curves show
minimum and maximum
voltage and amperage
output capabilities of unit.
Curves of other settings fall
between curves shown.
VOLTAGE
WELD AMPS
300
80
VOLTAGE
3-PHASE
OPERATION
400
60
GTAW-MAX
40
SMAW
GTAW 0%
25%
MIN
50%
20
75%
0
0
100
200
100%
300
400
500
AMPERAGE
3
Genuine Miller Accessories
Note: For best performance, do not run the XMT on
200 or 208 primary voltage when using the following
control options.
For All CC/CV Models Only
WC-24 Weld Control
#137 549
Packaged in a compact,
lightweight, non-metallic
enclosure, the WC-24
easily mounts directly
on the power source.
It’s designed for use with
Miller CV power sources supplying 24 VAC
and 14-pin receptacles. The control
includes a board-mounted potentiometer
which can alter the drive motor acceleration
rate to optimize arc starting performance.
For use with Spoolmatic 30A spool gun.
WC-115A Weld Control #137 546
This control operates on 115 VAC, and is
designed primarily for CC DC power sources.
It can also be used with CV power sources
or DC engine drives supplying 115 VAC.
When used with a CC source, the control
circuit functions in a voltage-sensing mode.
When used with a CV source, it functions
as a constant-speed circuit.
Standard features include a wire run-in
control and a drive motor acceleration
control which ensure optimum arc starting
performance, regardless of the type of
power source being used. The WC-115A
comes with a 10 ft (3 m), wall-type plug
power cord, and a 14-pin contactor cord.
4
Optima™ #043 389
A multipurpose,
microprocessor-based
pulse control for both
synergic MIG (wire
welding or GMAW) or
manual MIG pulsing.
Use this control with
the XMT 304 CC/CV
power source and any
Miller wire feeder, including automatic
feeders and spool guns. Includes a 25 ft
(7.6 m) cord with 14-pin plug. Features of
the control include:
• Manual MIG pulse mode allowing
operator to individually control peak
amperage, background amperage, pulses
per second and pulse width
• Synergic MIG pulse mode provides
synergic pulse spray programs
• Pulse spray transfer eliminates spatter
associated with the short circuit or
globular transfer process
• Both adaptive and non-adaptive pulsing
modes for a wide range of applications
• Standard MIG (GMAW) mode for
non-pulsed applications
• Microprocessor-based technology for
easy setup
• Convenient digital readout for better
repeatability. Readout displays program
number, pulse mode (adaptive or
non-adaptive), arc length (0–100) and
volts (for MIG only).
• Voltage-sensing leads are not required,
resulting in less cord clutter
• Includes a 25 ft (7.6 m) cord with
14-pin plug
• For best pulsing performance, use
4/0 weld cable and no more than 50 ft
(15.2 m) of total cable
Extension Cords for Optima
#043 725 25 ft (7.6 m)
#043 726 50 ft (15.2 m)
#043 727 75 ft (22.9 m)
For All Models
PC-300 Pulsed TIG (DC GTAW) Control
#042 297
Can be used with power sources that have
built-in high frequency, or it can be used
with an external high-frequency unit. The
control has two internally switchable
scales: a 0.5 – 20 pulses-per-second scale
for both inverter and non-inverter type
power sources, and a 10 – 300 pulses-persecond scale for inverter power sources
only. Control includes 8 ft (2.4 m) interconnecting cord and 115 VAC power cord.
Front panel controls provide:
• Peak amperage adjustment
• Background amperage adjustment
• Pulses-per-second adjustment
(0.5 – 20 pulses-per-second scale or
10 – 300 pulses-per-second scale)
• Percent-on-time control
• Amperage remote/panel control
• Output contactor on/off control
• Pulser on/off
• Power on/off
• Remote control receptacle (for remote
hand or foot controls)
HF-251D-1 HighFrequency Arc
Starter and Stabilizer
#042 388
A portable 115 volt,
250 amp unit.
Requires Secondary
Contactor.
Genuine Miller Accessories
Remote Controls
(continued)
Running Gear
RFCS-14 Foot
Control #043 554
Heavy-duty foot
current and contactor
control. Includes
20 ft (6 m) cord
and 14-pin plug.
RHC-14 Hand Control
#129 340
Miniature hand control
for remote current and
contactor control.
Dimensions: 4 x 4 x
3-1/4 in (102 x 102 x 82 mm). Includes
20 ft (6 m) cord and 14-pin plug.
RMLS-14 #129 337 14-pin plug
Momentary- and maintained-contact rocker
switch for contactor control. Push forward
for maintained contact and back for momentary contact. Includes 20 ft (6 m) cord.
RCC-14 Remote Contactor and Current
Control #151 086 14-pin plug
Rotary-motion fingertip control fastens to
TIG torch using two Velcro® straps.
Includes 28 ft (8.5 m) control cord.
RCCS-14 Remote Contactor and Current
Control #043 688
Up-and-down rotary-motion fingertip
control. Great for applications that require
a finer amperage control. Includes 28 ft
(8.5 m) control cord.
Extension Cords for Remote Controls
and 24 VAC Wire Feeders
#122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (22.8 m)
14-pin plug to 14-pin socket.
Note: Not for use with Optima or 60M Series.
Inverter Racks
Four or Six-Arc Welding System
New!
MIGRunner™ Cart #195 445
(For 300 A models only)
Small footprint and easily maneuverable,
with cylinder rack low enough that you do
not have to lift bottles. Durable, heavy-duty
ergonomic handles are designed for comfort.
Bottom tray will hold Coolmate™ 3 (sold
separately).
XMT Cylinder
Cart #042 537
Has adjustable
handles and is
slanted for
convenient
access to power
source front
panel controls.
Carries two
160 lb (72.6 kg) gas cylinders, or one gas
cylinder and one coolant system for TIG
(GTAW) welding. Feeder mounted to tray
above power source. Can be used with the
Maxtron™, Miller Arc Pak™ or XMT inverter
power supplies. Also accommodates
Radiator, Watermate™, or Coolmate™
coolant systems.
Universal
Carrying Cart
and Cylinder
Rack #042 934
Accommodates
XMT 304 power
source only, plus
gas cylinder up to
56 in (142.2 cm) high measuring 6 to 9 in
(15.2 to 22.8 cm) in diameter. Also provides
storage for auxiliary items such as electrodes,
helmets, gloves, etc. Can also be used with
Econotig™, Maxstar ® Series, Millermatic®
130XP and Millermatic® 150 power sources.
The Inverter Rack
conveniently houses
multiple XMT
power sources for
multiple welders.
Both 4-rack and
6-rack models
are available.
Features include:
Provision to parallel power sources or
common work connections
Two lifting eyes for transportation
Rugged skids for dragging or pushing
Customer can install up to a maximum
of 4 XMT 456 power sources
For detailed information on customized
Inverter Rack systems see Lit. Index No.
DC/18.81.
Water Coolant Systems
For more information, see the Miller Coolant
Systems literature sheet, Index No. AY/7.2.
Coolmate™ 3
#043 007 115 VAC
#043 008 230 VAC
For use with water-cooled torches rated up
to 600 amps. Unique paddle-wheel
indicator, external filter and easy-fill spout.
Coolmate™ V3 #043 009 115 VAC
For use with water-cooled torches rated up
to 500 amps. Vertical design conveniently
mounts to Miller cylinder rack in place of
one cylinder.
Coolmate™ 4 #042 288 115 VAC
For use with water-cooled torches rated up
to 600 amps. Tough molded polyethylene
case with carrying handle.
Coolant #043 810
Sold in cases of four 1-gallon recyclable
plastic bottles. Miller coolants contain a
base of ethylene glycol and deionized water
to protect against freezing to -37˚F (-38˚C)
or boiling to 227˚F (108˚C). Also contains a
compound that resists algae growth.
5
Wire Feeders
Spoolmatic® 30A #130 831
A 1-lb, air-cooled spool gun that extends
the weld process range by adding a handy
portable system for small wire MIG. Rated
200 A at 100% duty cycle. Includes 30 ft
(9.1 m) cable assembly. (WC-24 #137 549
for 14 pin.)
S-22P12 Wire Feeder #125 616
Compact, lightweight 24 VAC constantspeed semi-automatic wire feeder provides
portability in outdoor environments.
Primarily designed for gas-shielded wires.
Accommodates up to a 30 lb (13.6 kg),
12 in (304 mm) diameter spool. See Lit.
Index No. M/6.3.
S-74 DX #195 059
Wire feeder features process and weld
control and handles a variety of wires up to
1/8 in. See Lit. Index No. M/3.0.
XR Control #181 538
Push-pull wire feed system offers
unparalleled performance for aluminum
MIG welding.See Lit. Index No. M/1.7.
SuitCase 8VS™ #194 890
Lightweight, portable wire feeder for a
variety of wires up to .062 in. Holds up to an
8 in spool of wire. See Lit. Index No. M/6.4.
Super S-32P Wire Feeder #159 928
A compact, portable, voltage-sensing wire
feeder for .023 – 5/64 in (0.6 – 2.0 mm) flux
cored wire. See Lit. Index No. M/6.3.
Process Selector Control #042 872
This control is designed for use with dual
wire feeders, applications where electrical
isolation and/or polarity reversing of weld
current is required, and for easy welding
process changes.
Includes 115 VAC, 2 amp receptacle,
two 14-pin receptacles and a 10 ft (3 m)
14-pin cord.
22A Wire Feeder #193 006
Simple, Reliable, 24 VAC constant-speed
semiautomatic wire feeder, best suited for
small diameter wires. Accommodates up
to a 60 lb (27.2 kg) spool of welding wire
when using optional wire reel assembly.
See Lit. Index No. M/11.0.
6
60M Series
S-60M #131 794
D-60M #131 796
See Lit. Index No. M/2.4.
International-Style Connectors
Note: All XMT 304 power sources are equipped with
International-style connectors for secondary
connections. (Power source is shipped with two
50-mm male International-style plugs for use with
#4 to #1/0 AWG size cable.)
International-Style Connector Kit
#042 418 50 mm
Accepts #4 to #1/0 AWG cable size.
Required if male plugs shipped with power
source must be replaced, if additional plugs
are needed.
#042 533 70 mm
Accepts #1/0 or #2/0 AWG cable size.
Required if #1/0 or #2/0 AWG size cable is
to be used.
(Will accept Dinse™ or other International connectors.)
Extension Kit for International-Style
Cable Connectors
#042 419 50 mm
Accepts #1 or #2 AWG size cable.
#042 534 70 mm
Accepts #1/0 or #2/0 AWG size cable.
Used to adapt or extend weld and/or work
cables. Kit includes one male Internationalstyle plug and one in-line female
International-style receptacle.
Kit includes one International-style male
plug which attaches to the work and/or weld
cables and plugs into the International-style
receptacles on the power source.
International/Tweco®
Adapter #042 465
A one-piece adapter which
has an International-style
male plug (to power
source) on one end and a female Tweco
receptacle (for weld cable connection) on
other end.
International/Cam-Lok
Adapter #042 466
A one-piece adapter which
has an International-style
male plug (to power source) on one end
and a Cam-Lok receptacle (for weld cable
connection) on other end.
XMT 304 MIGRunner Components
™
New!
XMT® 304
MIGRunner™ #907 061
Comes Complete With:
XMT 304 power source
22A wire feeder
Roughneck™ C-4015 gun
Consumable kit
.035 and .045 in drive roll kit
Regulator/flow gauge with gas hose
NEW! MIGRunner Cart with cylinder rack
Bottom tray will hold optional Coolmate 3
(sold separately)
7
Ordering Information
Equipment and Options
Stock No.
Description
Qty.
XMT® 304 CC
#903 474
208-230/460 VAC with Auto-Link®
XMT® 304 CC/CV
#903 471
#903 471-01-1
#903 647
#903 473
#903 472
#903 522
208-230/460 VAC with Auto-Link®
208-230/460 VAC with Auto-Link® and Aux. Power
460 with CE
460/575 VAC with Auto-Link®
400 VAC, 50/60 Hz with Aux. Power and CE
400 VAC, 50/60 Hz
XMT® 304 MIGRunner™
#907 061
208-230/460 VAC with Auto-Link®. See page 7 for package components
#907 010
#907 010-01-1
#907 011
#907 012
230/460 VAC
230/460 VAC with Remote On/Off
575 VAC
400 VAC with CE
Power Source
®
XMT 456 CC/CV
Inverter Racks (full or empty)
Wire Feeders
Spoolmatic® 30A Spool Gun
S-22P12 Wire Feeder
22A Wire Feeder
XR Control
Super S-32P Wire Feeder
60M Series
S-74 DX
SuitCase 8VS™
See Lit. Index No. DC/18.81
#130 831
#125 616
#193 006
#181 538
#159 928
#131 794
#131 796
#195 059
#194 890
Guns
Roughneck C-Series
Gun Liners
Contact Tips
MIG Accessories
Optima™ MIG Pulse Control
Optima™ Extension Cords
WC-24
WC-115A
Process Selector Control
Power Source Data Cards
Includes 30 ft (9.1 m) cable assembly
See Lit. Index No. M/6.3
See Lit. Index No. M/11.0
See Lit. Index No. M/1.7
See Lit. Index No. M/6.3
S-60M. See Lit. Index No. M/2.4
D-60M. See Lit. Index No. M/2.4
See Lit. Index No. M/3.0
See Lit. Index No. M/2.4
See Lit. Index No. AY/17.0
See Lit. Index No. AY/17.0
See Lit. Index No. AY/17.0
#043 389
#043 725
#043 726
#043 727
#137 549
#137 546
#042 872
#043 390
#043 391
For XMT 304 and 456 CC/CV models only
25 ft (7.6 m)
50 ft (15.2 m)
75 ft (22.9 m)
For use with Spoolmatic 30A
For use with XMT 304 CC/CV
For use with 64M feeder
For use with XR-M feeder
TIG Accessories
PC-300 Pulsed DC TIG Control
HF-251D-1 HF Starter/Stabilizer
RFCS-14
RHC-14
RMLS-14
RCC-14
#042 297
#042 388
#043 554
#129 340
#129 337
#151 086
See Lit. Index No. AY/5.1
Foot control
Hand control
Rocker switch
Fingertip control
RCCS-14
#043 688
Fingertip control
#122 973
#122 974
#122 975
#043 725
#043 726
#195 445
25 ft (7.6 m)
50 ft (15.2 m)
75 ft (22.8m)
25 ft (7.6 m)
50 ft (15.2 m)
Accessories
Extension Cords (For 24 VAC wire
feeders and remote controls. Not to
be used with Optima, 60M or XR-M)
Extension Cords (115 VAC)
MIGRunner™ Cart
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Price