Miller Electric XMS 44 Owner`s manual

OM-223 839C
2008−05
Effective with serial number 242 780
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
XMS 44
Wire Feeder
OWNER’S MANUAL
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get the
job done and get it done right. We 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.
Like you, his customers couldn’t afford anything less. Miller products had
to be more than the best they could be. They had to be the best you could
buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.
Miller Electric manufactures a full line of
welders and welding related equipment.
For information on other quality Miller products, contact your local
Miller distributor to receive the latest full line catalog or individual
specification sheets.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Manufacturer’s Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Remote 7 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. 14-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Connecting Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Installing Wire Guide And Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Connecting Wire Feeder to Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Changing Cable Between Wire Feeder and XMS 4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Installing Wheels On Wire Feeder (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Switching On Unit And Recalling Factory Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Welding Process Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Trigger Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Setup Menu and Memory Menu Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Memory Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Jog And Purge Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Preparing Unit For MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Selecting Manual MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Selecting Synergic MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Selecting Synergic Pulsed MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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Declaration of Conformity for
European Community (CE) Products
. This information is provided for units with CE certification (see rating label on unit).
Manufacturer:
European Contact:
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that this product:
XMS 44
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Electromagnetic Compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995
Safety Requirements for Arc Welding Equipment part 1: IEC 60974-1 1990
Degrees of Protection Provided By Enclosures (IP Code): IEC 529 1989
Insulation Coordination For Equipment Within Low-Voltage Systems:
Part 1: Principles, Requirements And Tests. IEC 664-1 1992
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
dec_stat_milan1/07
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2007−04
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
During operation, keep everybody, especially children, away.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
ELECTRIC SHOCK can kill.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
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 touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Wear a safety harness if working above floor level.
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-223 839 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
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.
D 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.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
NOISE can damage hearing.
D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
Noise from some processes or equipment can
damage hearing.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
OM-223 839 Page 2
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
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.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
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.
FALLING UNIT can cause injury.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
READ INSTRUCTIONS.
D Read Owner’s Manual before using or servicing unit.
D Use only genuine replacement parts from the
manufacturer.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can cause injury.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
D
D
D
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-223 839 Page 3
1-4. California Proposition 65 Warnings
For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036–8002 (phone:
212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them, or using a
cable cover.
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
2. Arrange cables to one side and away from the operator.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-223 839 Page 4
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − DEFINITIONS
2-1. Manufacturer’s Warning Label Definitions
A
B
1
1.1
2
2.1
3
3.1
4
4.1
1.2
2.2
1.3
2.3
3.2
+
5
C
3.3
+
+
6
+
S-178 936
1. Warning! Watch Out! There are
possible hazards as shown by the
symbols.
2. Drive rolls can injure fingers
3. Welding wire and drive parts are at
welding voltage during operation −
keep hands and metal objects clear.
1 Electric shock can kill.
1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.
1.2 Protect yourself from electric shock by
insulating yourself from work and
ground.
1.3 Disconnect input plug or power before
working on machine.
2 Breathing welding fumes can be
hazardous to your health.
2.1 Keep your head out of the fumes.
2.2 Use forced ventilation or local exhaust
to remove the fumes.
2.3 Use ventilating fan to remove fumes.
3 Welding sparks can cause explosion
or fire.
3.1 Keep flammables away from welding.
Don’t weld near flammables.
3.2 Welding sparks can cause fires. Have
a fire extinguisher nearby and have a
watch person ready to use it.
3.3 Do not weld on drums or any closed
containers.
4 Arc rays can burn eyes and injure
skin.
4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.
5 Become trained and read the
instructions before working on the
machine or welding.
6 Do not remove or paint over (cover)
the label.
Do not discard this product with
general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collection facility.
Contact your local recycling office
or your local distributor for further
information.
OM-223 839 Page 5
1
1
2
3
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Drive rolls can injure fingers
Welding wire and drive parts
are at welding voltage during
operation − keep hands and
metal objects away.
3
2-2. Manufacturer’s Rating Labels
2-3. Symbols And Definitions
. Symbols found on product.
On
A
IP
Amperes
Degree Of
Protection
Read Instructions
V
Hz
U1
Purge
U2
Conventional
Load Voltage
I1
Off
Input
Volts
Alternating Current
Hertz
Circuit Breaker
Wire Feed
Primary Voltage
Gas Metal Arc
Welding (GMAW)
Line Connection
Remote
Water (Coolant)
Input
Water (Coolant)
Output
Primary Current
I2
. Symbols not shown here are detailed in this manual when they are relevant.
OM-223 839 Page 6
Rated Welding
Current
Output
X
Duty Cycle
SECTION 3 − INTRODUCTION
3-1. Specifications
Type of Input
Power
24 Volts AC
Single-Phase
7 Amperes
50/60 Hertz
Welding Power
Source Type
Wire Feed
Speed Range
Wire Diameter Range
0.8 mm − 1.8 mm
XMS 4000 Welding Power
Source
0.5 − 20 m/min
Max Spool Weight:
15 kg
Welding
Circuit
Rating
36 Volts,
400
Amperes,
30% Duty
Cycle
Overall
Dimensions
Weight
Length: 640 mm
Width: 225 mm
18 kg
Height: 435 mm
3-2. Remote 7 Receptacle Information
Pin
Pin Information
1
+10 volts DC supply voltage to remote control
2
GND Remote control circuit common
3
IREF 0 to 10 current control signal
4
VREF 0 to 10 voltage control signal
5
UP 0V/10V digital signal
6
DOWN 0V/10V digital signal
7
TYPE 0V/10V digital signal
Remote 7
. This remote receptacle cannot be used with a standard Miller remote control. A customer supplied remote control is required to use the remote
receptacle.
3-3. 14-Pin Plug Information
Pin*
J
I
B
N
H
G
A
K
L
C
M
F
D
E
Pin Information
A
24 volts AC with respect to socket G. Protected by circuit breaker CB1.
B
GND of communciation signals.
C
Serial communciation signal −485.
D
Serial communication signal +485.
E
Start motor signal to XMS 44.
F
Trigger switch signal to XMS 4000.
G
Circuit common for 24 volts AC circuit.
H
Wire feeder speed signal to XMS 44.
*The remaining pins are not used.
OM-223 839 Page 7
3-4. Connecting Welding Gun
1
2
3
Gun Securing Knob
Gun Block
Gun Outlet Wire Guide
Loosen knob, insert gun into block.
Position outlet wire guide as close
as possible to drive rolls without
touching. Tighten knob.
1
2
US Gun
3
4
5
Gun Trigger Plug
Gun Trigger Receptacle
. Contact
manufacturer for
equipment needed to connect
US Gun.
. Make cooling system connec4
tions as shown in Section 3-7.
5
1
2
Euro Gun
802 308
3-5. Installing Wire Guide And Drive Roll
1−2
1
2
Inlet Wire Guide
Intermediate Wire Guide
Install and secure inlet wire guide,
and intermediate wire guide.
3
Drive Roll (4)
Install drive rolls and turn drive roll
nut one click.
3
Correct Alignment
1
During maintenance intervals,
remove drive rolls, and clean
grooves using a wire brush. Check
general condition of drive rolls.
Aligning Wire Guide And Drive
Rolls:
View is from top of drive rolls
looking down with pressure assembly open.
3
Turn screw in or out until drive roll
groove lines up with wire guide.
2
Close pressure roll assembly.
Repeat for remaining drive rolls until all drive rolls line up with wire
guides as shown.
Incorrect Alignment
Tools Needed:
3/8 in
802 310-A
OM-223 839 Page 8
3-6. Circuit Protection
1
Circuit Breaker CB1
Circuit breaker CB1 is located inside the wire feeder as shown.
CB1 Protects the auxiliary 24 volt
AC circuit from overload.
1
3-7. Connecting Wire Feeder to Power Source
Make connections as shown. Be
sure connections are tight.
1
2
3
4
1
2
3
14 Pin Control Cord
Weld Cable (see Section 3-8
for connection inside wire
feeder)
Gas Hose
Connect hose to feeder using supplied clamp. Connect other end of
gas hose to the power source gas
cylinder or gas circuit.
7
5 6
4
5
4
Blue Quick Connect Fitting
(Coolant Output to Gun)
Connect blue to blue and red to red.
5
Red Quick Connect Fitting
(Coolant Return From Gun)
Connect blue to blue and red to red.
6
7
Work Cable Clamp (see
Section 3-8)
Cable Bundle Collar (see
Section 3-8)
1
2
OM-223 839 Page 9
3-8. Changing Cable Between Wire Feeder and XMS 4000
!
Disconnect power before
changing cables.
1
2
3
Access Door
Clamp
Plastic Collar
Connect weld cable to terminals behind access door.
3
Remove screws securing door,
clamp and collar. Make cable connections. Reinstall clamp, collar,
and door.
2
3
1
Tools Needed:
3-9. Installing Wheels On Wire Feeder (Optional)
1
2
3
Wheels
Bars
Screws
Remove rubber feet from wire feeder.
Install only wheels on feeder if smaller
dimensions are desired, unit will be
used on level floors, or if optional turntable is used.
Install wheels and bars for increased
stability on uneven floors.
1
3
1
Tools Needed:
OM-223 839 Page 10
SECTION 4 − OPERATION
4-1. Control Panel
7
8
1
2
5
3
6
9
10
4
5
6
7
MIG Gun Connector
Red Quick Connect Fitting (Coolant
Return From Gun).
Blue Quick Connect Fitting (Coolant
Output To Torch)
Remote Control Receptacle
Handle
Panel
D1 − (Display 1)
Displays values and parameters for selected
welding process.
15
14
16 17 18
19
20
21
22
28
29
4
11
26
27
12
D2 − (Display 2)
Displays values and parameters for selected
welding process.
9
E1 (Encoder Control 1)
Use control to change values and parameters
that appear on D1.
10 E2 (Encoder Control 2)
13
3
23
8
Use control to change values and parameters
that appear on D2.
11 P1 (Trigger Selection Push Button)
24
2
25
Allows selecting desired trigger mode.
12 P2 (Memory/Setup Push Button)
Allows selecting Memory and Setup menus for
MIG welding.
13 P8 (Jog/Purge Push Button)
Performs jog and purge operations.
1
14 L1 ON means that D1 shows the voltage
value
15 L2 ON means that D1 shows the Trim
value
16 L3 ON means that D2 shows Wire Speed
value
17 L4 ON means that D2 shows Amperage
value
18 L5 ON means that D2 shows Material
Thickness value
19 L6 selection is Manual MIG welding
20 L7 selection is Synergic MIG welding
21 L8 selection is Synergic Pulsed MIG
welding
22 L9 selection is Synergic Double Pulsed
MIG welding
23 L10 ON selects 2 times trigger function
24 L11 ON selects 4 times trigger function
25 L12 ON selects 3 levels trigger function
26 L13 ON selects Setup menu
27 L14 On selects Memory menu
28 L15 ON selects Jog function
29 L16 ON selects Purge function
OM-223 839 Page 11
4-2. Switching On Unit And Recalling Factory Parameters
Install power source and wire feeder according to supplied Owner’s Manuals. Turn
On welding power source.
Displays D1 and D2 will show the wire
feeder software version. Welding system is
ready to weld with the factory-set default
values or or the values and parameters of
the last weld.
When Stick or TIG welding the wire feeder
is energized but does not work. Displays
D1 and D2 will show hyphens. When MIG
welding, wire feeder is always on. Displays
D1 and D2 will show set voltage and wire
speed (or correlated parameters) and the
measured welding voltage and current
while welding.
To recall factory-set parameters:
Turn power source Off then On again. Immediately press wire feeder P1 and P3. Release P1 and P3 when MEM CLR appears
on D1 and D2. Turn power source Off when
DON appears on D1. All parameters will return to factory default settings the next time
unit is turned on.
. Write down any parameters that need
to be restored before performing this
procedure.
4-3. Welding Process Selection
L6
L7
L8
L9
MIG welding selection is made on the power source. Wire Feeder shows the welding
process selected with four LED’s.
Values and parameters that appear on D1
and D2 are either factory default settings or
last settings entered for the selected process.
L6 selection is Manual MIG welding. See
Section 4-9.
D1 value is welding voltage; default is 18.5
volts (range is 10 to 50 volts).
D2 value is wire feed speed; default is 5
m/min (range is 1 m/min to 20 m/min).
L2 selection is Synergic MIG welding (nonpulsed). See Section 4-10.
OM-223 839 Page 12
D1 value is trim, default is 0.0 T (range is
−5.0 T to 5.0 T).
D2 value is wire feed speed (from min to
max value according to welding curve
selection).
. When L7 is flashing, material transfer
in the arc is by large droplets (globular
transfer) and produces considerable
spatter. This is the result of selecting a
specific material, wire, gas, voltage,
and current combination. To avoid this
situation, Synergic Pulsed MIG welding with the same parameter combination is recommended. When L7 is On
continuously (not flashing), material
transfer in the arc is either short circuit
(Short Arc) or by small droplets (Spray
Transfer). Both MIG processes provide a stable arc and minimum spatter.
L8 selection is Synergic Pulsed MIG welding. See Section 4-12.
D1 value is Trim, default is 0.0 (range is
−5.0 to 5.0).
D2 value is wire feed speed (from minimum
to maximum value according to welding
curve selection).
L9 selection is Synergic Double Pulsed
MIG welding. See Section 4-12.
D1 value is trim, default is 0.0 (range is −5
to 5).
D2 value is wire feed speed (from min to
max value according to welding curve
selection).
4-4. Trigger Mode Selection
L10
L11
L12
P1
. Always check and set a trigger mode.
If trigger mode is undefined for a welding process, select the desired mode.
Trigger mode can be set for Manual MIG,
Synergic MIG, Synergic Pulsed MIG, and
Synegic Double Pulsed MIG welding to
change when output power is present at
the weld connectors. In Manual MIG, Synergic MIG, Synergic Pulsed MIG, and Synergic Double Pulsed MIG welding, pressing P1 will change trigger mode, but D1 and
D2 will not change values.
Press P1 to select the desired trigger
mode:
L10 ON selects 2 times trigger function.
When trigger is pressed, welding starts.
When trigger is released, welding stops.
L11 ON selects 4 times trigger function.
When trigger is pressed, welding starts.
When trigger is released, welding continues.
When trigger is pressed and released a
second time, welding stops.
L12 ON selects 3 levels trigger function.
When trigger is pressed, welding starts
with level 1 parameters.
When trigger is released, welding continues with main parameters.
When trigger is pressed a second time,
welding continues at level 2 parameters.
When trigger is released the second time,
welding stops.
L12 trigger mode is useful for aluminum
and for a crater fill sequence.
In Manual MIG process, 2 times and 4
times trigger mode can be selected.
In Synergic MIG process, 2 times, 4 times
and 3 levels can be selected.
In Synergic Pulsed MIG process, 2 times,
4 times, and 3 levels can be selected.
In Synergic Double Pulsed MIG process, 2
times, 4 times, and 3 levels can be selected.
4-5. Setup Menu and Memory Menu Selection
L13 and L14 are generally OFF.
L13
L14
P2 selects the Setup Menu and the advance programming of MIG welding and to
memorize and manage personal welding
parameters in MIG welding.
Press P2 to select Setup Menu. L13 is ON.
P2
Press P2 a second time to select Memory
Menu. L14 is ON.
Press P2 again to exit Setup and Memory
Menu. L13 and L14 are OFF.
In order to complete Setup and/or Memory
procedures you have to exit these menus.
L13 and L14 must be off.
. In Setup Menu and Memory Menu you
cannot weld. This avoids setting errors in the welding parameters and in
the memorized welding parameters.
OM-223 839 Page 13
4-6. Setup Menu
Press P2 to enter SET UP menu.
Setup allows viewing and changing default
parameter values for all welding processes
for the desired weld characteristics.
D1 shows the welding parameter.
D2 shows the parameter value.
E1 changes the welding parameter.
E2 changes the parameter value.
P2 allows to exit setup Menu and Advanced Programming and to save the
changed parameters.
. Incorrect settings in any process can
result in a program with undesirable
weld characteristics. Setup should
only be used by operators familiar with
various welding processes and parameters.
Setting Menu Type
Use E1 to select SET (setup) SHO (short)
on D1 and D2 (default setting).
Use E2 to change D2 to FULL.
. MENU SHORT only shows basic pa-
rameters for welding processes. SETUP FULL shows all parameters for
welding processes. Menu selection is
set when exiting the Setup Menu.
To set menu type, proceed as follows:
Press P2 to enter Setup menu.
4-7. Memory Menu
Press P2 to enter Memory menu.
D1 shows the first free memory position or
the last memory used.
E1 changes the memory position number
from P.01 to P.99.
Any memory position contains all the selected MIG welding parameters in the Wire
Feeder and in the Power Source.
When a memorized welding point is loaded
the Wire Feeder and the Power Source is
set accordingly.
Verify the Power Source status before
welding, if needed.
D1 shows the memory position.
E1 changes the memory position.
D2 shows the action you can perform on
the memory position.
E2 changes the action on the memory position.
When D2 shows Ld (load), you can load in
the welder the parameters in the memory
position selected by D1.
When D2 shows Sto (storage), you can
memorize the actual welding parameters in
the memory position selected by D1.
When D2 shows dEL (delete), you can delete the parameters memorized in the
memory position selected by D1.
In order to confirm the action, press P2 until
D1 and D2 flash.
Release P2 and wait until flashing stops.
The action is now performed and the welder exits the Memory menu.
. Do not perform any operation on the
welder when in Memory menu to prevent incorrect weld parameters and
poor operation.
4-8. Jog And Purge Selection
L15
L16
P3
. If a function is selected and not used
within several seconds, the LED will
turn off .
To use the jog and purge function, proceed
as follows:
Pressing P3 once selects jog. Pressing P8
a second time selects purge.
When L15 illuminates, press and hold P3 to
perform jog function.
OM-223 839 Page 14
Jog feeds welding wire without weld output
power applied to the wire.
In Jog mode, D1 shows JOG and D2
shows wire feed speed.
Use E2 to change wire feed speed setting.
. Jog will be performed if gun trigger is
pressed and held without striking a
welding arc. Front panel Jog is recommended.
When L16 illuminates, press and hold P3 to
perform purge function.
. Purge is used to remove impurities and
fill the gas hose with shielding gas.
Pre−Gas is a similar function, but only
operates at the beginning of a welding
process. Purge can be performed in
the TIG process by pressing the torch
trigger without striking an arc.
4-9. Preparing Unit For MIG Welding
To select MIG welding process, proceed as follows:
Follow safety precautions according to
Section 1.
Prepare unit according to Section 3.
1
4
Using a cable with a proper
adapter, connect gun to the MIG
gun connector.
Connect work clamp cable to the
WORK connector on the power source.
2
If using a water-cooled gun,
connect input coolant hose to blue
quick connect fitting
Connect return coolant hose to
red quick connect fitting.
2
3
3
Check coolant level after attaching
torch coolant hoses and running cooler.
Be sure coolant appears in upper half of
indicator. Add coolant if necessary (see
Power Source manual).
4
If a remote control is desired,
connect it to the Remote Control
receptacle
Turn unit On.
1
Allow time for unit to complete its start
up cycle.
Set MIG welding process on the Power
Source and check L1, L2, L3 and L4 on
the Wire Feeder.
Purge air from the gas hose using P3
pushbutton (see Section 4-8).
OM-223 839 Page 15
4-10. Selecting Manual MIG Welding
E1
D1
D2
E2
L3
L1
L4
L6
P1
P2
Set Manual MIG welding process on the power source. L6 is On.
In Manual MIG mode, the operator may need to adjust main welding
parameters for specific arc characteristics. Wire feed speed and arc
voltage will appear on D1 and D2.
During Setting :
D1 value is default voltage setting of 18.5 V (range is 10 V to 50 V).
L1 is On.
Use E1 to change voltage.
D2 value is default wire feed speed setting of 5.0 m/min (range is 1.0
m/min to 20.0 m/min). L3 is On.
Use E2 to change wire feed speed.
While Welding:
D1 shows the measured welding voltage in volts. L1 is On.
D2 shows the measure welding current in amperes. L4 is On.
Set wire speed and welding voltage with E1 and E2.
Select trigger mode using P1 push button (see Section 4-4).
If necessary, use P2 to adjust the welding parameters.
Purge air from gun hose using P3 pushbutton. (see Section 4-8).
Manual MIG Welding Advanced Settings
To change all values list, unit must be SETUP FULL. To set unit to
SETUP FULL, proceed as follows:
Press P2 to enter SET UP menu.
Select SET FULL on D1 and D2 (see Section 4-6).
Setting Inductance
Press P2 to enter SET UP menu.
Use E1 to select on D1 ind. D2 shows 100.wi
If necessary, use E2 to adjust inductance value (range is 1% to
200%).
. Higher inductance setting produces a softer weld puddle and
less spatter, but arc starts may be more difficult. Lower induc-
OM-223 839 Page 16
tance setting produces a stiffer weld puddle and more spatter,
but arc starts may be easier.
Wire Feed Speed Unit (only in SETUP FULL)
Use E1 to change D1 to Uni.
D2 value is the default setting of mpm (meters per minute). D2 shows
IS.
Use E2 to change D2 to IPM (inches per minute). D2 shows Inc.
L3 is always on in MIG Manual welding.
Setting Pre-Gas (only in SETUP FULL)
Use E1 to change D1 to PrE.
D2 value is default setting of 0.0 s (range is 0.0 s to 10.0 s).
Use E2 to change D2 value.
Setting Post-Gas (only in SETUP FULL)
Use E1 to change D1 to PoS.
D2 value is default setting of 0.1 s (range is 0.0 s to 10.0 s).
Use E2 to change D2 value.
Setting BurnBack (only in SETUP FULL)
Use E1 to change D1 to bur.
D2 value is default setting of Aut (range is 1% to 200%).
Auto is a setting below 1% that provides an automatic burnback time.
Use E2 to change D2 value.
Setting Run-In (only in SETUP FULL)
Use E1 to change D1 to rin.
D2 value is default setting of Aut (range is 1% to 200%).
Auto is a setting below 1% that provides an automatic run-in time.
Use E2 to change D2 value.
Run-In is the speed of the wire feed before arc starting in percent of
the set wire speed. It is used for improving arc starts.
4-11. Selecting Synergic MIG Welding
E1
D1
D2
E2
L7
P1
L1
Set Synergic MIG welding process on the
power source. L7 is ON.
In Synergic MIG mode, the operator may
need to adjust welding data (wire type, wire
diameter, and gas type) and only one weld
parameter. Generally, wire feed speed is
adjusted and the synergic process automatically sets appropriate weld voltage.
Synergic welding also sets many secondary welding parameters automatically for
improved weld quality.
Trim parameter appears on D1 and D2:
D1 value is default trim setting of 0.0 T
(range is −5.0 T to 5.0 T).
D2 value is default wire feed speed setting
of 5.0 m/min (minimum (MIN), maximum
(MAX), or default (DEF) values are arbitrary based on set welding data). Use P2
and E2 to change this display to amperes
or to the thickness of the material.
While Setting Parameters:
- L2 ON means that D1 shows Trim value.
- L3 ON means that D2 shows the wire
speed in meter/min or inch/min.
- L4 ON means that D2 shows the set welding current in amperes.
- L5 ON means that D2 shows the thickness of material to weld.
While Welding:
- D1 shows the measured welding voltage
in Volts. L1 is ON.
- D2 shows the measured welding current
in amperes. L4 is ON.
Set wire speed, welding current or material
thickness and welding voltage with E2 and
E1.
Select trigger mode using P1 pushbutton
(see Section 4-4).
If necessary, use P2 to adjust the welding
parameters.
Purge air from gun hose using P3 pushbutton (see Section 4-8).
P2
P3
L2
L3
L4
L5
Setting Trim
D1 value is default trim setting of 0.0 T
(range is −5.0 T to 5.0 T).
Trim is an arbitrary value related to MIG arc
length. Higher values produce a longer and
hotter arc. Lower values produce a shorter
and cooler arc. Recommended value for
trim is default setting or near 0.0T. L2 is On.
Synergic MIG Welding Advanced Settings
To change all values list, unit must be SETUP FULL. To set unit to SETUP FULL, proceed as follows:
Press P2 to enter SET UP menu.
Select SETUP FULL on D1 and D2 (see
Section 4-6).
Setting Main Welding Regulations
Enter SET UP and select rEG on D1 with
E1.
D2 shows the main parameter and E2
changes it.
When D2 shows SPE (wire speed) the
main regulation is the speed of the welding
wire. L3 is ON.
When D2 shows A (ampere) the main regulation is the welding current in Amperes. L4
is ON.
When D2 shows thc (thickness) the main
regulation is the material thickness in mm.
L5 is ON.
. The modification to the main welding
regulation is confirmed when exiting
the Set Up Menu.
. The measured welding current can be
different from the set value. This difference can be greater if there are
changes on the default parameters
and if the welding conditions are not
conventional. Setting amperage must
be considered a reference.
. Material thickness setting is a reference value only.
Setting Inductance
Press P2 to enter SET UP menu.
Use E1 to select on D1 ind. D2 shows 100.
If necessary, use E2 to adjust inductance
value (range is 1% to 200%).
. Higher inductance setting produces a
softer weld puddle and less spatter, but
arc starts may be more difficult. Lower
inductance setting produces a stiffer
weld puddle and more spatter, but arc
starts may be easier.
Wire Feed Speed Unit (only in SETUP
FULL)
See Section 4-10.
Setting Pre−Gas (only in SETUP FULL)
See Section 4-10.
Setting Post-Gas (only in SETUP FULL)
See Section 4-10.
Setting Burnback (only in SETUP FULL)
See Section 4-10.
Setting Run-In (only in SETUP FULL)
See Section 4-10.
Setting 3 Level Trigger Mode (only in
SETUP FULL)
Use E1 to change D1 to 3L.1
D2 value is the default setting of 130%
(range is 20% to 200%).
Use E2 to change D2 value.
Use E1 to change D1 to 3L.2
D2 value is the default setting of 80%
(range is 20% to 200%).
Use E2 to change D2 value.
Use E1 to change D1 to 3L.r
D2 value is the default setting of 0.5 s
(range is 0.1 s to 0.5 s).
This value is the ramp time in seconds to
reach the following level wire speed.
OM-223 839 Page 17
4-12. Selecting Synergic Pulsed MIG Welding
E1
D1
D2
E2
L7
L8
P1
L1
Set Synergic Pulsed MIG welding process on the
power source. L7 is On.
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 aluminum. In Synergic
Pulsed MIG mode, the operator may need to adjust welding data (wire type, wire diameter, and
gas type) and only one weld parameter. Generally, wire feed speed is adjusted and the synergic
process automatically sets appropriate weld
voltage. Synergic welding also sets many secondary welding parameters automatically for improved weld quality.
Trim parameter appears on D1 and D2:
D1 value is default trim setting of 0.0 T (range is
−5.0 T to 5.0 T).
D2 value is default wire feed speed setting of 5.0
m/min (minimum (MIN), maximum (MAX), or default (DEF) values are arbitrary based on set
welding data). Use P2 and E2 to change this display to amperes or to the thickness of the weld.
While Setting Parameters:
- L2 ON means that D1 shows Trim value.
- L3 ON means that D2 shows the wire speed in
meter/min or inch/min.
- L4 ON means that D2 shows the set welding
current in amperes.
- L5 ON means that D2 shows the thickness of
material to weld.
L2
P2
P3
L3
L4
L5
To change all values list, unit must be SETUP
FULL. To set unit to SETUP FULL, proceed as
follows:
Press P2 to enter SET UP menu.
Select SETUP FULL on D1 and D2 (see Section
4-6).
Setting Main Welding Regulation
See Section 4-11.
Setting Inductance in Synergic Pulsed MIG
Welding
Press P2 to enter SET UP menu.
Use E1 to select on D1 ind. D2 shows 100.
If necessary, use E2 to adjust inductance value
(range is 1% to 200%).
This parameter is related to Pulse Width. Higher
values give a hotter welding arc.
. Change these parameters as little as possible because the factory settings are preferred for most applications.
Big changes can affect the arc stability and
weld performance.
In general, remain in the 70% to 130%
range.
Wire Feed Speed Unit (only in SETUP FULL)
See Section 4-10.
Setting Pre-Gas (only in SETUP FULL)
See Section 4-10.
Setting Post-Gas (only in SETUP FULL)
While Welding:
See Section 4-10.
- D1 shows the measured welding voltage in
Volts. L1 is ON.
- D2 shows the measured welding current in amperes. L4 is ON.
Set wire speed, welding current or material thickness and welding voltage with E2 and E1.
Select trigger mode using P1 pushbutton (see
Section 4-4).
If necessary, use P2 to adjust the welding parameters.
Purge air from gun hose using P3 pushbutton
(see Section 4-8).
Setting Burnback (only in SETUP FULL)
Setting Trim
See Section 4-11.
Synergic Pulsed MIG Welding Advanced Settings
OM-223 839 Page 18
See Section 4-10.
Setting Run-In (only in SETUP FULL)
See Section 4-10.
Setting 3 Level Trigger Mode
See Section 4-11.
Some metals weld better using the Synergic
Pulsed Welding process due to the unique pulsing of the welding arc. Heat generated in the
workpiece is generally lower and the arc characteristics produce a better weld bead appearance
especially on aluminum. The Synergic Double
Pulsed MIG process allows control all parameters to produce high quality welds on aluminum.
. Incorrect
settings in Synergic Double
Pulsed Welding process can result in a program with undesirable weld characteristics.
Setup should only be used by operators familiar with various welding processes and
parameters. In some cases, standard Synergic Pulsed MIG welding can produce better welds.
Press P2 to enter SET UP menu.
Use E1 to change D1 to 2P.F.
Use E2 to change D2 value.
The range of this setting is 0.1 Hz to 5.0 Hz. This
setting allows changing double pulse frequency
in hertz (cycles per second). A recommended
frequency is approximately 1 hertz.
Use E1 to change D1 to 2P.C.
D2 value is default setting of 50%.
Use E2 to change D2 value.
The range of this setting is 25% to 75%. This setting allows changing the time that the pulse is at
high output. A lower setting will produce less
heating at the welding puddle.
Use E1 to change D1 to 2P.O. D2 value is default
setting of 20%. Use E2to change D2 value. The
range of this setting is 20% to 80%. This setting
allows changing the difference in high wire feed
speed and low wire feed speed in percent of the
wire feed speed setting. For example, if the main
wire feed speed is set at 5 M and 2P.0 setting in
D2 is 40%, the wire feed speed will change between 4 m/min and 6 m/min. A recommended
setting is 20%.
Setting Synergic Double Pulsed MIG
. Synergic Double Pulsed MIG process is selected at the power source or recalled in the
wire feeder using Synergic Double Pulsed
programs. All Double Pulse parameters are
selected on the wire feeder. All other MIG
parameters are the same as standard
Pulsed MIG process.
Use E1 to change D1 to 2P.A. D2 value is the default setting of 0.0. Use E2 to change D2 value.
The range of this setting is −5.0 to 5.0.
This setting allows changing the low end of trim
in double pulse and the main setting for trim will
be the low end. A higher 2P.A setting will produce
a longer and hotter arc and lower setting will produce a shorter and cooler arc.
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
!
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
3 Months
Replace
Damaged Or
Unreadable
Labels
Clean And
Tighten
Weld
Terminals
Replace Damaged
Gas Hose
Repair Or Replace
Cracked Cables
And Cords
6 Months
Clean
Drive
Rolls
Blow Out Or
Vacuum Inside
5-2. Help Displays
The XMC 44 microprocessor controls all internal parameters of the
units.
In case of failure, D1 and D2 will show the following Error Signals.
HLP 100
Indicates that the 24 volt AC supplied to the unit is low.
Verify the supply to the unit and the circuit breaker status on both the
wire feeder and on the power source.
HLP 101
Indicates that the current in the motor is too high.
Verify that the wire has not stopped.
HLP 102
Indicates that the voltage on the motor is too high.
Verify that the wire has not stopped.
HLP 103
Indicates that there is a short circuit in the motor or in the cabling.
Verify that the motor and cabling are functioning.
HLP 104
Indicates that the motor speed is too low or the encoder on the motor
is giving incorrect signals.
Verify that the motor has not stopped and check the cabling of the encoder.
HLP 105
Indicates a communication error between the power source and the
wire feeder.
Verify that all the connectors in the path from the control board of the
power source and the motor board of the wire feeder are correctly
fixed.
HLP 106
Indicate that there is a communication error in the RS 485.
Verify that all the connectors in the path from the control board of the
power source and the motor board of the wire feeder are correctly
fixed.
OM-223 839 Page 19
5-3. Troubleshooting
Problem
Unit is completely inoperative.
Solution
Check continuity of Power switch S1, and replace if necessary.
Reset circuit breaker CB1 if open.
Check input power source. See welding power source Technical Manual.
Wire does not feed, unit completely inop- Turn Power switch On.
erative.
Check 14−pin receptacle connections.
Check input power or the CB
Wire does not feed.
Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s
Manual.
Have Factory Authorized Service Agent check drive motor and control board PC1.
Wire feeds erratically.
Readjust hub tension and drive roll pressure.
Use correct size drive roll (see Parts List).
Clean or replace dirty or worn drive roll.
Remove weld spatter around nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Check wiring between Motor Board and Encoder
Electrode wire feeding stops or feeds
erratically during welding.
Realign drive rolls.
Check hub assembly (see Parts List).
Wire feeds as soon as power is applied. Check gun trigger. See gun Owner’s Manual.
Gas valve rattles loudly and wire feeds Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
slowly or erratically.
Gas does not flow; wire feeds.
Check gas valve and flowmeter.
Wire feeds, but gas does not flow with Check coil voltage and connections of gas valve. Check continuity of coil. Replace if necessary.
gun trigger pressed.
Check continuity of Purge switch, and replace if necessary.
Software or visualization problems.
Recall factory parameters as explained in this manual.
Call a Factory Authorized Service Agent.
Wire feeds and electrode wire is ener- Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace if necessary.
gized, but gas flow is irregular.
Clear blockage in gas hose or replace hose.
Clear blockage in gun. See gun Owner’s Manual.
Motor runs at full speed.
Check motor control board and connections, and replace if necessary.
Check wiring between Motor Board and Encoder
Wire drive motor coasts (no brake at trig- Check motor control board PC1 and connections, and replace if necessary.
ger release).
Meter does not work properly.
OM-223 839 Page 20
Recall factory parameters as explained in this manual.
SECTION 6 − ELECTRICAL DIAGRAM
May 9, 2005
OM-223 839 Page 21
SECTION 7 − PARTS LIST
. Hardware is common and not available unless listed.
11
10
9
8
7
12
13
14
15
2
3
16
4
1
5
6
17
20
21
33
18
22
19
32
24
31
30
29
28
27
26
23
25
.
May 9, 2005
Figure 7-1. Main Assembly
OM-223 839 Page 22
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-1. Main Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
. . . . . . . . . . . . . . . . . . V57052030
. . . . . . . . . . . . . . . . . . . 028066243
. . . . . . . . . . . . . . . . . . V56014271
. . . . . . . . . . . . . . . . . . . 000178937
. . . . . . PC2 . . . . . . . V57084045
. . . . . . CB1 . . . . . . . . 000083432
. . . . . . . . . . . . . . . . . . . 000151187
. . . . . . . . . . . . . . . . . . V56122270
. . . . . . . . . . . . . . . . . 000178936A
. . . . . . . . . . . . . . . . . . . 000208015
. . . . . . . . . . . . . . . . . . . 156034004
. . . . . . . . . . . . . . . . . +V56121269
. . . . . . . . . . . . . . . . . . V56161034
. . . . . . . . . . . . . . . . . . V56031169
. . . . . . . . . . . . . . . . . +V56118268
. . . . . . . . . . . . . . . . . +V57060135
. . . . . . . . . . . . . . . . . . V56079197
. . . . . . . . . . . . . . . . . . . 000204326
. . . . . . . . . . . . . . . . . . V56122272
. . . . . . . . . . . . . . . . . . V27028202
. . . . . . . . . . . . . . . . . . . 056076216
. . . . . . ELV . . . . . . . . 056061042
. . . . . . . . . . . . . . . . . . . 556049372
. . . . . . . . . . . . . . . . . . . 556049373
. . . . . . . . . . . . . . . . . . V56118267
. . . . . . . . . . . . . . . . . +V17026131
. . . . . . . . . . . . . . . . . . V57094063
. . . . . . . . . . . . . . . . . . . 556049368
. . . . . . . . . . . . . . . . . . . 556049369
. . . . . . . . . . . . . . . . . . V16029155
. . . . . . . . . . . . . . . . . . . 756005024
. . . . . . PC1 . . . . . . . V57084166
. . . . . . . . . . . . . . . . . . . 000193919
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
Euro adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire drive system with encoder motor . . . . . . . . . . . . . . . . . . . . .
Board protection Al. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, warning, gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit board, motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit breaker, 10 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, side Al. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover Al. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reel, holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Baffle, intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, rear Al. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Baffle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Collar, stauff din 1593 15.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tool tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, side rear Al. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, receptacle, 14 pin M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power connector M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, solenoid, 24 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, coupling, blue fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, coupling, red fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, front Al. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, receptacle, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, coupling, blue fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, coupling, red fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, front, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flange, euro adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit board, control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-223 839 Page 23
. Hardware is common and not available unless listed.
24
25
23
22
21
20
19
1
18
2
4
3
17
4
5
16
6
15
7
8
14
9
10
11
12
13
May 9, 2005
Figure 7-2. Wire Drive Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-2. Wire Drive Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
. . . . . . . M . . . . . . . . V57010029
. . . . . . . . . . . . . . . . . . . 000601966
. . . . . . . . . . . . . . . . . . . 156018021
. . . . . . . . . . . . . . . . . . . 000602213
. . . . . . . . . . . . . . . . . . . 656005026
. . . . . . . . . . . . . . . . . . . 000604673
. . . . . . . . . . . . . . . . . . . 656005027
. . . . . . . . . . . . . . . . . . . 000166338
. . . . . . . . . . . . . . . . . . . 000166337
. . . . . . . . . . . . . . . . . . . 000072010
. . . . . . . . . . . . . . . . . . . 000108943
. . . . . . . . . . . . . . . . . . . 000173618
. . . . . . . . . . . . . . . . . . . 000602239
. . . . . . . . . . . . . . . . . . . 000174609
. . . . . . . . . . . . . . . . . . . 000602009
. . . . . . . . . . . . . . . . . . . 000172075
. . . . . . . . . . . . . . . . . . . 000601872
. . . . . . . . . . . . . . . . . . . 000602213
. . . . . . . . . . . . . . . . . . . 000010224
. . . . . . . . . . . . . . . . . . . 000166071
. . . . . . . . . . . . . . . . . . . 000089562
. . . . . . . . . . . . . . . . . . . 000085244
. . . . . . . . . . . . . . . . . . . 000089477
. . . . . . . . . . . . . . . . . . . . 00089243
. . . . . . . . . . . . . . . . . . . 000202562
OM-223 839 Page 24
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
Motor, 24 VDC, 60 W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever, mounting pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing adapter gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, insulating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carrier, drive roll, keyed, 24 pitch . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, .250-20 x .500 soc hd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, .250-20 x 1.250 soc hd hex gr 8 . . . . . . . . . . . . . . . . . . . .
Carrier, drive roll, with component, 24 pitch . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, spring CS .187 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever, mounting pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, cupped stl, .328 ID x .812 OD x .125 . . . . . . . . . . . . . . .
Spring, cprsn .770 OD x .105 wire x 1.225 . . . . . . . . . . . . . . . . . .
Knob, tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
1
4
1
1
1
2
2
2
1
1
4
4
1
1
2
1
2
2
2
2
1
Table 7-1. Drive Roll And Wire Guide Kits (4 Drive Roll)
. Base selection of drive rolls upon the following recommended usages:
1. V-Grooved rolls for hard wire.
2. U-Grooved rolls for soft and soft shelled cored wires.
3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4. V-Knurled rolls for hard shelled cored wires.
5. Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved).
Drive Roll
Wire Diameter
Metric
Fraction
Decimal
0.6 mm
0.023/0.025 in
0.023/0.025 in
0.8 mm
0.030 in
Kit No.
Wire Guide
Part No.
Type
Inlet
Intermediate
087 132
087 130
V-Grooved
056 192
056 206
0.030 in
046 780
053 695
V-Grooved
056 192
056 206
0.9 mm
0.035 in
0.035 in
046 781
053 700
V-Grooved
056 192
056 206
1.0/1.2 mm
0.035/0.045 in
0.035/0.045 in
N/A
189 285
V-Grooved
156 193
056 207
1.0 mm
0.040 in
0.040 in
191 917
053 696
V-Grooved
056 192
056 206
1.2 mm
0.045 in
0.045 in
046 782
053 697
V-Grooved
056 193
056 207
1.6 mm
1/16 in
0.062 in
046 784
053 699
V-Grooved
056 195
056 209
0.9 mm
0.035 in
0.035 in
044 750
072 000
U-Grooved
056 192
056 206
1.2 mm
0.045 in
0.045 in
046 785
053 701
U-Grooved
056 193
056 207
1.3 mm
0.052 in
0.052 in
046 786
053 702
U-Grooved
056 193
056 207
1.6 mm
1/16 in
0.062 in
046 787
053 706
U-Grooved
056 195
056 209
2.0 mm
5/64 in
0.079 in
046 788
053 704
U-Grooved
056 195
056 209
0.9 mm
0.035 in
0.035 in
046 782
132 958
V-Knurled
056 192
056 206
1.2 mm
0.045 in
0.045 in
046 793
132 957
V-Knurled
056 193
056 207
1.3 mm
0.052 in
0.052 in
046 794
132 956
V-Knurled
056 193
056 207
1.6 mm
1/16 in
0.062 in
046 795
132 955
V-Knurled
056 195
056 209
1.8 mm
0.068-0.072 in
0.068-0.072 in
089 985
132 959
V-Knurled
056 195
056 209
2.0 mm
5/64 in
0.079 in
046 796
132 960
V-Knurled
056 195
056 209
1.2 mm
0.045 in
0.045 in
083 319
083 489
U-Cogged
056 193
056 207
1.3 mm
0.052 in
0.052 in
083 320
083 490
U-Cogged
056 193
056 207
1.6 mm
1/16 in
0.062 in
046 800
053 708
U-Cogged
056 195
056 209
2.0 mm
5/64 in
0.079 in
046 801
053 710
U-Cogged
056 195
056 209
OM-223 839 Page 25
Notes
Effective January 1, 2008
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, ITW Welding Products Italy warrants to its original retail
purchaser that new Miller equipment sold after the effective date
of this limited warranty is free of defects in material and
workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted 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 such a failure within the warranty time
periods. All warranty time periods start on the date the
equipment was delivered to the original retail purchaser, not to
exceed eighteen months after the equipment is shipped to an
International distributor.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
*
*
*
*
*
*
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
RFCS Foot Controls
IHPS Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
HF Units, Including HFP-14 Pendant
Running Gear/Trailers
Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
1 Year — Parts and Labor Unless Specified
*
*
5.
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
2 Years — Parts and Labor
*
4.
Original main power rectifiers limited to only include
SCRs, diodes, and discrete rectifier components
where applicable
Inverters (Input and Output Rectifiers Only)
DC 253 & 403 Rectifier (April 06>)
Migmatic 171 (April 06>)
6 Months — Batteries
6.
90 Days — Parts
*
*
*
*
*
*
*
MIG Guns
Induction Heating Coils and Blankets
Remote Controls
Accessory (Kits)
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated 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 COMMERCIAL/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: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase 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 F.O.B., Factory at ITW Welding Products
Group Europe or F.O.B. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
TO THE EXTENT PERMITTED BY 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 CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
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.
milan_warr 2008-02
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
Country
Zip/Postal Code
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Service and Repair
Replacement Parts
Owner’s Manuals
ITW Welding Products Italy S.r.l.
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2008 Miller Electric Mfg. Co. 1/08
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39 (0) 2982901
Fax: 39 (0) 298290-203
email: miller@itw−welding.it