A DC18-8 XMT 304-456_A DC18-8 XMT 304-456.qxd

®
XMT 304/456 CC/CV
Quick
Specs
Heavy Industrial Applications
Processes
Construction
Shipbuilding
Railroad
Truck/Trailer Manufacturing
Fabrication
Repair Shops
Rental Fleets
MIG (GMAW)/Pulsed MIG (GMAW-P)
Stick (SMAW)
TIG (GTAW)
Flux Cored (FCAW)
Air Carbon Arc Cutting and Gouging
(CAC-A)
Issued August 2010 • Index No. DC/18.8
Multiprocess Welding
Power Source
Input Power
304: Requires 3- or 1-Phase Power
456: Requires 3-Phase Power
Output Power
304: 10 – 35 V, 5 – 400 A
456: 10 – 38 V, 5 – 600 A
Weight
304: Net: 79.5 lb (36.1 kg) Ship: 88.6 lb (40.2 kg)
456: Net: 118 lb (53.5 kg) Ship: 129 lb (58.5 kg)
The Power of Blue .
®
Wind Tunnel Technology ™
protects electrical
components and PC
boards from contamination.
Lightweight, aerospacegrade aluminum case
offers protection with the
benefit of reduced weight.
Fan-On-Demand™ cooling
system operates only
when needed, reducing
noise, energy use and the
amount of contaminants
pulled through machine.
Inverter arc control
technology provides
greater puddle control
for superior 6010 Stick
electrode performance.
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.
XMT 456 CC/CV
with Manual Link
Line voltage compensation
keeps welding output
constant even if input
power varies by +/-10%.
Adaptive Hot Start™ increases the output
amperage at the start of a weld if
necessary, eliminating electrode sticking.
XMT 304 CC/CV
with Auto-Link®
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.
Process selector switch
reduces the number of
control setup combinations
without reducing any
features.
115 VAC auxiliary power provides 10 amps
of circuit-breaker-protected power for water
circulators, etc. Standard on XMT 456,
optional on XMT 304.
Power source is warranted for 3 years, parts and labor.
Original main power rectified parts are warranted for 5 years.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
www.MillerWelds.com
XMT 304 CC/CV Specifications
®
(Subject to change without notice.)
Input
Power
Rated Output
at 60%
Duty Cycle
Voltage
Range in
CV Mode
Amperage
Range in
CC Mode
Max.
Open-Circuit
Voltage
Amps Input at Rated Load Output, 60 Hz,
208 V 230 V 400 V 460 V 575 V KVA KW
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
Dimensions
Weight
H: 17 in
(432 mm)
W: 12-1/2 in
(318 mm)
D: 24 in
(610 mm)
79.5 lb
(36.1 kg)
Certified to both the Canadian and U.S. Standards for welding equipment.
XMT 304 CC/CV Control Panel
®
5
1
6
2
Additional Features
Auto-Link® circuit automatically links the
power source to primary voltage being
applied (230/460 or 460/575 VAC, single- or
three-phase).
3
7
4
Ultra-tough, polycarbonate-blended cover
for control panel protects front controls
from damage.
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
Dinse-style weld disconnects provide
high-quality weld cable connections.
XMT 304 CC/CV Performance Data
®
CC VOLT/AMP CURVE
DUTY CYCLE CHART
500
CV VOLT/AMP CURVE
100
100
80
80
3-PHASE AND
460 VAC 1-PHASE OPERATION
SMAW-MAX
300
230 VAC 1-PHASE OPERATION
150
VOLTS
60
250
225
200
VOLTS
WELDING AMPERES
400
GTAW-MAX
40
GTAW-MIN
SMAW-MIN
0%
20
60
MAX
40
20
25%
MIN
50%
75%
100
10
15
20
25 30
40
DUTY CYCLE
2
50 60 70 80 90 100
0
100%
0
100
200
300
AMPS
0
400
500
0
100
200
300
AMPS
400
500
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.
Open-Circuit
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)
118 lb
(53.5 kg)
Certified to both the Canadian and U.S. Standards for welding equipment.
XMT 456 CC/CV Control Panel
®
Additional Features
1
Primary voltage display shows what primary
voltage the power source is linked for without
removing the side panels. Saves time and
assures you that the power source has been
correctly linked for available input voltage.
2
4
5
6
3
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!
7
Note: XMT 456 is equipped with Stud for ring-lug output connections.
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)
Optional remote on/off provides ability to turn
power source on or off when it is located away
from your work.
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
CC VOLT/AMP CURVES
% DUTY CYCLE
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
XMT MIGRunner Components
®
™
XMT ® 304 MIGRunner ™ #951 343
Comes Complete With:
XMT 304 CC/CV power source
22A wire feeder
Bernard® Q400 MIG Gun
Consumables
.035/.045 in drive roll kit
Regulator/flow gauge with gas hose
MIGRunner Cart with cylinder rack
Bottom tray will hold optional Coolmate 3
(sold separately)
Genuine Miller Accessories
Process Selector Control #042 872
Designed for use with dual wire feeders,
applications where electrical isolation and/or
polarity reversing of weld current is required,
and for welding process changes. Includes
115 VAC/2 amp receptacle, two 14-pin
receptacles and a 10 ft (3 m) 14-pin cord.
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.
4
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
#242 208 025 25 ft (7.6 m)
#242 208 050 50 ft (15 m)
#242 208 080 80 ft (24.3 m)
14-pin plug to 14-pin socket.
Note: Not for use with Optima or 60M Series.
Genuine Miller Accessories
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 sources and any Miller wire feeder,
including automatic feeders and spool
guns. Includes a 25 ft (7.6 m) cord with
14-pin plug.
Extension Cords for Optima
#242 205 025 25 ft (7.6 m)
#242 205 050 50 ft (15 m)
#242 205 080 80 ft (24.3 m)
WC-24 Weld Control
#137 549
Designed for use with
Miller CV power sources
supplying 24 VAC and
14-pin receptacles. For
use with Spoolmatic
30A spool gun.
WC-115A Weld Control
#137 546-01-1
Operates on 115 VAC
and is designed for
power sources without
a 14-pin receptacle. For
use with Spoolmatic 30A spool gun. Includes
10 ft (3 m) wall-type plug and power cord.
HF-251D-1
High-Frequency Arc
Starter and Stabilizer
#042 388
Portable 250 amp, 60%
duty cycle unit adds
high frequency to the
welding circuit to help start the arc when
using the DC TIG (GTAW) process.
Operates on 115 VAC, 50/50 Hz. See Lit.
Index No. AY/5.1.
(continued)
Inverter Racks
Running Gear
304 Cart
Dual feeder/456 Cart
Four or Six-Arc Welding System
The Inverter Rack conveniently houses
multiple XMT power sources for multiple
welders. Both 4-pack and 6-pack 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.
MIGRunner ™ Cart
#195 445 (For 304 models only)
Running Gear Cylinder Rack
#300 408 (For dual feeders and 456 model)
Small footprint and easily maneuverable,
with cylinder rack low enough that you do
not have to lift bottles.
XMT Cylinder Cart
#042 537
Carries two 160 lb
(72.6 kg) gas
cylinders, or one
gas cylinder and
one coolant system
for TIG (GTAW)
welding. Feeder
mounts to tray above power source.
Universal Carrying
Cart and Cylinder
Rack #042 934
(For 304 models
only)
Holds power source,
and gas cylinder
up to 56 in (142.2 cm) high measuring
6 to 9 in (15.2 to 22.8 cm) in diameter.
Protective Cover
#195 478
Mildew and water
resistant, odor-free
cover protects your
machine’s finish. For
300/350 A inverters:
XMT, Maxstar and
Dynasty.
5
Genuine Miller Accessories
(continued)
Wire Feeders/Guns
Water Coolant Systems
For more information, see the Miller Coolant
Systems literature sheet, Index No. AY/7.2.
Coolmate V3
Coolmate 3
SuitCase® X-TREME™ 8VS #951 181
SuitCase® X-TREME™ 12VS #951 184
Lightweight, portable wire feeder for a
variety of wires up to .062 in. Holds up to
an 8 in (8VS) or 12 in (12VS) spool of wire.
Operates on open-circuit voltage eliminating
the need for a control/power cord. See Lit.
Index No. M/6.41.
70 Series
S-74S #951 196
S-74D #951 198
S-74DX #951 200
Heavy-duty, industrial, constant-speed
24 VAC semiautomatic wire feeders
with available digital meters. Ideal for
high-duty-cycle MIG welding (GMAW) and
Flux Cored welding (FCAW). Accommodates
a wide variety of wire sizes and types.
Comes with FREE Bernard® Q™-Gun! See
Lit. Index No. M/3.0.
Coolmate 4
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.
SuitCase® 8RC #951 186
SuitCase® 12RC #951 188
Lightweight, portable wire feeder for a
variety of wires up to .062 in. Holds up to
an 8 in (8RC) or 12 in (12RC) spool of wire.
Operates using 14-pin control receptacle.
See Lit. Index No. M/6.5.
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)
required for use with 14-pin receptacles,
order separately.
Roughneck ® C-Series MIG Guns
See Lit. Index No. AY/17.0.
XR™-S Control #300 601
XR™-D Control #300 678
The updated XR Controls offer unsurpassed
performance and reliability for feeding
aluminum and other difficult-to-feed wire
types. Models include .035 in and factoryinstalled 3/64 in drive rolls. See Lit. Index
No. M/1.7.
6
Ironmate™ Flux Cored Guns
See Lit. Index No. AY/16.0.
FC-1260
#195 732 10 ft (3 m)
#195 729 15 ft (4.6 m)
FC-1260LM
#194 912 10 ft (3 m)
#194 911 15 ft (4.6 m)
FC-1150
#194 864 10 ft (3 m)
#194 863 15 ft (4.6 m)
TIG Coolant
#043 810
Sold in multiples
of 4. Pre-mixed
low-conductivity
Miller coolant
contains ethylene
glycol and deionized water to protect from
freezing and boiling -37˚ to 227˚F (-38˚ to
108˚C). Coolant contains 2.4% algae growth
inhibitor. 1-gallon plastic recyclable bottles.
Genuine Miller Accessories
(continued)
Cable Connectors and Adapters
Note: XMT 304 power sources are equipped with
Dinse-style connectors for secondary connections.
Dinse/Tweco® Adapter
#042 465
Dinse/Cam-Lok Adapter
#042 466
One-piece adapter with Dinse-style male
plug (to power source) on one end and
female receptacle (Tweco or Cam-Lok for
weld cable connection) on other end.
Dinse-Style Connectors
#042 418
Accepts #4 AWG to #1/0 cable size.
#042 533
Accepts #1/0 to #2/0 AWG cable size.
Kit includes one Dinse-style male plug
which attaches to the work and/or weld
cables and plugs into the Dinse-style
receptacles on the power source.
Extension Kit for Dinse-Style
Cable Connectors
#042 419
Accepts #4 AWG to #1/0 cable size.
#042 534
Accepts #1/0 to #2/0 AWG cable size.
Used to adapt or extend weld and/or
work cables. Kit includes one male
Dinse-style plug and one in-line female
Dinse-style receptacle.
7
Ordering Information
Power Source and Options
Stock No.
Description
XMT® 304 CC/CV
#903 471
#903 471-01-1
#903 473
#903 472
208-230/460 VAC with Auto-Link®
208-230/460 VAC with Auto-Link® and Auxiliary Power
460/575 VAC with Auto-Link®
400 VAC, 50/60 Hz with Auxiliary Power and CE
XMT® 304 MIGRunner™ Package
#951 343
208-230/460 VAC with Auto-Link®
XMT® 456 CC/CV
#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
Inverter Racks (full or empty)
Qty.
See Lit. Index No. DC/18.81
Accessories
Process Selector Control
#042 872
HF-251D-1 HF Starter/Stabilizer
#042 388
See Lit. Index No. AY/5.1
RFCS-14
#043 554
Foot control
RHC-14
#129 340
Hand control
RMLS-14
#129 337
Rocker switch
RCC-14
#151 086
Fingertip control
RCCS-14
#043 688
Fingertip control
Extension Cords (For 24 VAC wire
feeders and remote controls)
Optima™ MIG Pulse Control
See page 4. Not to be used with Optima or 60M
#043 389
Optima™ Extension Cords
See page 5
WC-24
#137 549
For use with Spoolmatic 30A and power sources with 14-pin
WC-115A
#137 546-01-1
For use with Spoolmatic 30A and power sources without 14-pin
Running Gear
MIGRunner™ Cart
#195 445
For XMT 304 models only
Running Gear Cylinder Rack
#300 408
For dual feeders and XMT 456 model
XMT Cylinder Cart
#042 537
For all models
Universal Carrying Cart and Cylinder Rack
#042 934
For XMT 304 models only
Protective Cover
#195 478
Wire Feeders/Guns
SuitCase® X-TREME™ 8VS/12VS
#951 181 / #951 184
See Lit. Index No. M/6.41
SuitCase® 8RC / 12RC
#951 186 / #951 188
See Lit. Index No. M/6.5
XR™-S Control
#300 601
Standard model with wire feed speed digital display, jog/purge,
run-in control, and trigger hold. See Lit. Index No. M/1.7
XR™-D Control
#300 687
Enhanced model has same features as XR-S model plus advanced digital
and programming capabilities. See Lit. Index No. M/1.7
70 Series
#951 196
#951 198
#951 200
S-74S. See Lit. Index No. M/3.0
S-74D. See Lit. Index No. M/3.0
S-74DX. See Lit. Index No. M/3.0
Spoolmatic® 30A Spool Gun
#130 831
Requires WC-24 for use with 14-pin receptacles
Bernard® Q™-Series MIG Guns
See Welding Components and Parts Guide
Ironmate Flux Cored Guns
See Lit. Index No. AY/16.0
Water Coolant Systems
See page 6. See Lit. Index No. AY/7.2
Cable Connectors and Adapters
See page 7
™
Date:
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Distributed by:
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