Miller Electric Welder XMS 44 User Manual

OM-223 839B  
200607  
Processes  
MIG (GMAW) Welding  
Flux Cored (FCAW) Welding  
Description  
Wire Feeder  
XMS 44  
Wire Feeder  
OWNER’S MANUAL  
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TABLE OF CONTENTS  
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).  
NOTE  
Manufacturer:  
European Contact:  
ITW Welding Products Italy S.r.l.  
Via dell’Industria, 55  
36030 Sarcedo  
Vincenza, Italy  
Phone: 39(0445)367706  
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_Milan_6/05  
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SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING  
som _3/05  
Y
Warning: Protect yourself and others from injury — read and follow these precautions.  
1-1. Symbol Usage  
Means Warning! Watch Out! There are possible hazards  
with this procedure! The possible hazards are shown in  
the adjoining symbols.  
This group of symbols means Warning! Watch Out! possible  
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.  
Consult symbols and related instructions below for necessary actions  
to avoid the hazards.  
Y
Marks a special safety message.  
. Means “Note”; not safety related.  
1-2. Arc Welding Hazards  
Y
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.  
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Turn off all equipment when not in use.  
Do not use worn, damaged, undersized, or poorly spliced cables.  
Do not drape cables over your body.  
If earth grounding of the workpiece is required, ground it directly  
with a separate cable.  
Do not touch electrode if you are in contact with the work, ground,  
or another electrode from a different machine.  
D
D
Y
Y
Only qualified persons should install, operate, maintain, and  
repair this unit.  
Do not touch electrode holders connected to two welding ma-  
chines at the same time since double open-circuit voltage will be  
present.  
During operation, keep everybody, especially children, away.  
D
Use only well-maintained equipment. Repair or replace damaged  
parts at once. Maintain unit according to manual.  
ELECTRIC SHOCK can kill.  
D
D
D
Wear a safety harness if working above floor level.  
Keep all panels and covers securely in place.  
Clamp work cable with good metal-to-metal contact to workpiece  
or worktable as near the weld as practical.  
Insulate work clamp when not connected to workpiece to prevent  
contact with any metal object.  
Do not connect more than one electrode or work cable to any  
single weld output terminal.  
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  
groundedequipment is a hazard.  
D
D
D
D
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Do not touch live electrical parts.  
Wear dry, hole-free insulating gloves and body protection.  
Insulate yourself from work and ground using dry insulating mats  
or covers big enough to prevent any physical contact with the work  
or ground.  
Do not use AC output in damp areas, if movement is confined, or if  
there is a danger of falling.  
Use AC output ONLY if required for the welding process.  
If AC output is required, use remote output control if present on  
unit.  
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.  
D
D
D
FUMES AND GASES can be hazardous.  
D
Additionalsafety precautions are required when any of the follow-  
ing 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 unavoid-  
able or accidental contact with the workpiece or ground. For these  
conditions, use the following equipment in order presented: 1) a  
semiautomaticDC constant voltage (wire) welder, 2) a DC manual  
(stick) welder, or 3) an AC welder with reduced open-circuit volt-  
age. In most situations, use of a DC, constant voltage wire welder  
is recommended. And, do not work alone!  
Welding produces fumes and gases. Breathing  
these fumes and gases can be hazardous to your  
health.  
D
D
Keep your head out of the fumes. Do not breathe the fumes.  
If inside, ventilate the area and/or use local forced ventilation at the  
arc to remove welding fumes and gases.  
D
D
If ventilation is poor, wear an approved air-supplied respirator.  
Read and understand the Material Safety Data Sheets (MSDSs)  
and the manufacturer’s instructions for metals, consumables,  
coatings, cleaners, and degreasers.  
Work in a confined space only if it is well ventilated, or while  
wearing an air-supplied respirator. Always have a trained watch-  
person nearby. Welding fumes and gases can displace air and  
lower the oxygen level causing injury or death. Be sure the breath-  
ing air is safe.  
Do not weld in locations near degreasing, cleaning, or spraying op-  
erations. The heat and rays of the arc can react with vapors to form  
highly toxic and irritating gases.  
Do not weld on coated metals, such as galvanized, lead, or  
cadmiumplated 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
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
D
D
Properly install and ground this equipment according to its  
Owner’s Manual and national, state, and local codes.  
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  
groundedreceptacle outlet.  
D
D
D
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When making input connections, attach proper grounding conduc-  
tor first double-check connections.  
Frequently inspect input power cord for damage or bare wiring −  
replace cord immediately if damaged bare wiring can kill.  
OM-223 839 Page 1  
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ARC RAYS can burn eyes and skin.  
BUILDUP OF GAS can injure or kill.  
D
D
Shut off shielding gas supply when not in use.  
Always ventilate confined spaces or use  
approved air-supplied respirator.  
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 fil-  
ter lenses to protect your face and eyes when welding or watching  
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).  
HOT PARTS can cause severe burns.  
D
D
D
Wear approved safety glasses with side shields under your  
helmet.  
D
D
Do not touch hot parts bare handed.  
Allow cooling period before working on gun or  
torch.  
To handle hot parts, use proper tools and/or  
wear heavy, insulated welding gloves and  
clothing to prevent burns.  
Use protective screens or barriers to protect others from flash,  
glare and sparks; warn others not to watch the arc.  
D
Wear protective clothing made from durable, flame-resistant mate-  
rial (leather, heavy cotton, or wool) and foot protection.  
WELDING can cause fire or explosion.  
MAGNETIC FIELDS can affect pacemakers.  
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  
D
D
Pacemaker wearers keep away.  
Wearers should consult their doctor before  
going near arc welding, gouging, or spot  
welding operations.  
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.  
NOISE can damage hearing.  
D
D
D
Do not weld where flying sparks can strike flammable material.  
Protect yourself and others from flying sparks and hot metal.  
Noise from some processes or equipment can  
damagehearing.  
Be alert that welding sparks and hot materials from welding can  
easily go through small cracks and openings to adjacent areas.  
D
Wear approved ear protection if noise level is  
high.  
D
D
Watch for fire, and keep a fire extinguisher nearby.  
Be aware that welding on a ceiling, floor, bulkhead, or partition can  
cause fire on the hidden side.  
CYLINDERS can explode if damaged.  
D
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).  
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.  
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.  
D
D
Protect compressed gas cylinders from excessive heat, mechani-  
cal shocks, physical damage, slag, open flames, sparks, and arcs.  
D
D
Do not use welder to thaw frozen pipes.  
Install cylinders in an upright position by securing to a stationary  
support or cylinder rack to prevent falling or tipping.  
Remove stick electrode from holder or cut off welding wire at  
contact tip when not in use.  
D
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Keep cylinders away from any welding or other electrical circuits.  
Never drape a welding torch over a gas cylinder.  
D
D
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Wear oil-free protective garments such as leather gloves, heavy  
shirt, cuffless trousers, high shoes, and a cap.  
Never allow a welding electrode to touch any cylinder.  
Never weld on a pressurized cylinder explosion will result.  
Remove any combustibles, such as a butane lighter or matches,  
from your person before doing any welding.  
Use only correct shielding gas cylinders, regulators, hoses, and fit-  
tings designed for the specific application; maintain them and  
associated parts in good condition.  
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B  
for hot work and have a fire watcher and extinguisher nearby.  
D
D
Turn face away from valve outlet when opening cylinder valve.  
Keep protective cap in place over valve except when cylinder is in  
use or connected for use.  
FLYING METAL can injure eyes.  
D
Welding, chipping, wire brushing, and grinding  
cause sparks and flying metal. As welds cool,  
they can throw off slag.  
Wear approved safety glasses with side  
shields even under your welding helmet.  
D
D
Use the right equipment, correct procedures, and sufficient num-  
ber of persons to lift and move cylinders.  
Read and follow instructions on compressed gas cylinders,  
associated equipment, and Compressed Gas Association (CGA)  
publication P-1 listed in Safety Standards.  
D
OM-223 839 Page 2  
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1-3. Additional Symbols For Installation, Operation, And Maintenance  
FIRE OR EXPLOSION hazard.  
MOVING PARTS can cause injury.  
D
Do not install or place unit on, over, or near  
combustiblesurfaces.  
Do not install unit near flammables.  
D
D
Keep away from moving parts such as fans.  
Keep all doors, panels, covers, and guards  
closed and securely in place.  
D
D
D
Have only qualified persons remove doors,  
panels, covers, or guards for maintenance as  
necessary.  
Reinstall doors, panels, covers, or guards  
when maintenance is finished and before re-  
connecting input power.  
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.  
D
D
D
Use lifting eye to lift unit only, NOT running  
gear, gas cylinders, or any other accessories.  
Use equipment of adequate capacity to lift and  
support unit.  
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 servic-  
ing unit.  
D
Use only genuine Miller/Hobart replacement  
parts.  
H.F. RADIATION can cause interference.  
D
High-frequency (H.F.) can interfere with radio  
navigation, safety services, computers, and  
communicationsequipment.  
Have only qualified persons familiar with  
electronic equipment perform this installation.  
OVERUSE can cause OVERHEATING  
D
D
Allow cooling period; follow rated duty cycle.  
Reduce current or reduce duty cycle before  
starting to weld again.  
D
D
Do not block or filter airflow to unit.  
D
D
The user is responsible for having a qualified electrician prompt-  
ly correct any interference problem resulting from the installa-  
tion.  
If notified by the FCC about interference, stop using the  
equipmentat once.  
STATIC (ESD) can damage PC boards.  
D
D
Have the installation regularly checked and maintained.  
D
Put on grounded wrist strap BEFORE handling  
boards or parts.  
Use proper static-proof bags and boxes to  
store, move, or ship PC boards.  
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
ARC WELDING can cause interference.  
MOVING PARTS can cause injury.  
D
Electromagnetic energy can interfere with  
sensitive electronic equipment such as  
computers and computer-driven equipment  
such as robots.  
Be sure all equipment in the welding area is  
electromagneticallycompatible.  
D
D
Keep away from moving parts.  
Keep away from pinch points such as drive  
rolls.  
D
D
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D
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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 elec-  
tronic equipment.  
WELDING WIRE can cause injury.  
D
Do not press gun trigger until instructed to do  
so.  
Be sure this welding machine is installed and grounded  
according to this manual.  
D
Do not point gun toward any part of the body,  
other people, or any metal when threading  
welding wire.  
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.  
1-4. California Proposition 65 Warnings  
Y
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.)  
For Gasoline Engines:  
Y
Engine exhaust contains chemicals known to the State of  
California to cause cancer, birth defects, or other reproductive  
harm.  
For Diesel Engines:  
Y
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  
reproductiveharm. Wash hands after handling.  
Y
Diesel engine exhaust and some of its constituents are known  
to the State of California to cause cancer, birth defects, and  
other reproductive harm.  
OM-223 839 Page 3  
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1-5. Principal Safety Standards  
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,  
from Global Engineering Documents (phone: 1-877-413-5184, website:  
www.global.ihs.com).  
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:  
8004636727 or in Toronto 4167474044, website: www.csain-  
ternational.org).  
Practice For Occupational And Educational Eye And Face Protection,  
ANSI Standard Z87.1, from American National Standards Institute, 11  
West 42nd Street, New York, NY 100368002 (phone: 2126424900,  
website: www.ansi.org).  
Recommended Safe Practices for the Preparation for Weldingand Cut-  
ting 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).  
Standard for Fire Prevention During Welding, Cutting, and Other Hot  
Work, NFPA Standard 51B, from National Fire Protection Association,  
P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (phone:  
6177703000,website: www.nfpa.org).  
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-  
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA  
022699101(phone: 6177703000, website: www.nfpa.org).  
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,  
from Compressed Gas Association, 1735 Jefferson Davis Highway,  
Suite 1004, Arlington, VA 222024102 (phone: 7034120900, web-  
site: www.cganet.com).  
OSHA, Occupational Safety and Health Standards for General Indus-  
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,  
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-  
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there  
are 10 Regional Offices−−phone for Region 5, Chicago, is  
3123532220,website: www.osha.gov).  
Code for Safety in Welding and Cutting, CSA Standard W117.2, from  
Canadian Standards Association, Standards Sales, 178 Rexdale  
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.  
2. Arrange cables to one side and away from the operator.  
3. Do not coil or drape cables around your body.  
Welding current, as it flows through welding cables, will cause electro-  
magnetic 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  
committees judgment, has not demonstrated that exposure to power-  
frequency 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.  
4. Keep welding power source and cables as far away from opera-  
tor as practical.  
5. Connect work clamp to workpiece as close to the weld as possi-  
ble.  
About Pacemakers:  
Pacemaker wearers consult your doctor before welding or going near  
welding operations. If cleared by your doctor, then following the above  
procedures is recommended.  
To reduce magnetic fields in the workplace, use the following  
procedures:  
OM-223 839 Page 4  
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SECTION 2 DEFINITIONS  
2-1. Manufacturer’s Warning Label Definitions  
1. Warning! Watch Out! There are  
possible hazards as shown by the  
symbols.  
A
B
C
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.  
1
2
1.1  
2.1  
1.2  
1.3  
2
Breathing welding fumes can be  
hazardous to your health.  
2.2  
2.3  
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
4
5
3.1  
4.1  
3.2  
3.3  
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.  
6
5
Become trained and read the  
instructions before working on the  
machine or welding.  
+
6
Do not remove or paint over (cover)  
the label.  
S-178 936  
Do not discard this product with  
general waste.  
Reuse or recycle Waste Electrical  
and Electronic Equipment (WEEE)  
by disposing at a designated collec-  
tion facility.  
Contact your local recycling office  
or your local distributor for further  
information.  
OM-223 839 Page 5  
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1
Warning! Watch Out! There  
are possible hazards as  
shown by the symbols.  
1
2
3
Drive rolls can injure fingers  
Welding wire and drive parts  
are at welding voltage during  
operation keep hands and  
metal objects away.  
2
3
2-2. Manufacturer’s Rating Labels  
2-3. Symbols And Definitions  
Symbols found on product.  
NOTE  
On  
Off  
Input  
Output  
Amperes  
Volts  
AlternatingCurrent  
Circuit Breaker  
Duty Cycle  
A
IP  
V
Hz  
U1  
X
Degree Of  
Protection  
Hertz  
Wire Feed  
Gas Metal Arc  
Welding (GMAW)  
Read Instructions  
Purge  
Primary Voltage  
Line Connection  
Water (Coolant)  
Input  
Water (Coolant)  
Output  
Remote  
Conventional  
Load Voltage  
Rated Welding  
Current  
Primary Current  
U2  
I1  
I2  
. Symbols not shown here are detailed in this manual when they are relevant.  
OM-223 839 Page 6  
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SECTION 3 INTRODUCTION  
3-1. Specifications  
Welding  
Circuit  
Rating  
Type of Input  
Welding Power  
Source Type  
Wire Feed  
Speed Range  
Overall  
Dimensions  
Wire Diameter Range  
Weight  
Power  
36 Volts,  
400  
Amperes,  
30% Duty  
Cycle  
24 Volts AC  
Single-Phase  
7 Amperes  
0.8 mm 1.8 mm  
Length: 640 mm  
Width: 225 mm  
Height: 435 mm  
XMS 4000 Welding Power  
Source  
0.5 20 m/min  
23 kg  
Max Spool Weight:  
15 kg  
50/60 Hertz  
3-2. Remote 7 Receptacle Information  
Pin  
1
Pin Information  
+10 volts DC supply voltage to remote control  
GND Remote control circuit common  
IREF 0 to 10 current control signal  
VREF 0 to 10 voltage control signal  
UP 0V/10V digital signal  
2
3
4
5
6
DOWN 0V/10V digital signal  
7
TYPE 0V/10V digital signal  
Remote 7  
Note: 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*  
Pin Information  
A
B
C
D
E
F
24 volts AC with respect to socket G. Protected by circuit breaker CB1.  
GND of communciation signals.  
Serial communciation signal 485.  
J
A
E
K
I
B
Serial communication signal +485.  
N
L
C
H
Start motor signal to XMS 44.  
M
F
D
G
Trigger switch signal to XMS 4000.  
G
H
Circuit common for 24 volts AC circuit.  
Wire feeder speed signal to XMS 44.  
*The remaining pins are not used.  
OM-223 839 Page 7  
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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 connec-  
4
1
5
2
Gun  
Euro  
802 308  
3-5. Installing Wire Guide And Drive Roll  
1
2
Inlet Wire Guide  
12  
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.  
During maintenance intervals,  
remove drive rolls, and clean  
grooves using a wire brush. Check  
general condition of drive rolls.  
3
Correct Alignment  
1
Aligning Wire Guide And Drive  
Rolls:  
View is from top of drive rolls  
looking down with pressure assem-  
bly 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 un-  
til 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  
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3-6. Circuit Protection  
1
Circuit Breaker CB1  
Circuit breaker CB1 is located in-  
side 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
14 Pin Control Cord  
for connection inside wire  
feeder)  
3
Gas Hose  
Connect hose to feeder using sup-  
plied clamp. Connect other end of  
gas hose to the power source gas  
cylinder or gas circuit.  
7
6
5
4
Blue Quick Connect Fitting  
(Coolant Output to Gun)  
5
4
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
Work Cable Clamp (see  
7
Cable Bundle Collar (see  
1
2
OM-223 839 Page 9  
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3-8. Changing Cable Between Wire Feeder and XMS 4000  
Y
Disconnect power before  
changing cables.  
1
2
3
Access Door  
Clamp  
Plastic Collar  
Connect weld cable to terminals be-  
hind access door.  
3
Remove screws securing door,  
clamp and collar. Make cable con-  
nections. 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 turn-  
table is used.  
Install wheels and bars for increased  
stability on uneven floors.  
1
3
1
Tools Needed:  
OM-223 839 Page 10  
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SECTION 4 OPERATION  
4-1. Control Panel  
1
2
MIG Gun Connector  
Red Quick Connect Fitting (Coolant  
Return From Gun).  
7
8
5
3
Blue Quick Connect Fitting (Coolant  
Output To Torch)  
4
5
6
7
Remote Control Receptacle  
Handle  
6
9
10  
Panel  
D1 (Display 1)  
Displays values and parameters for selected  
welding process.  
15  
14  
8
D2 (Display 2)  
16 17 18  
19  
20  
21  
22  
Displays values and parameters for selected  
welding process.  
28  
29  
4
9
E1 (Encoder Control 1)  
Use control to change values and parameters  
that appear on D1.  
26  
27  
10 E2 (Encoder Control 2)  
12 13  
11  
Use control to change values and parameters  
that appear on D2.  
3
2
23  
24  
11 P1 (Trigger Selection Push Button)  
Allows selecting desired trigger mode.  
12 P2 (Memory/Setup Push Button)  
25  
Allows selecting Memory and Setup menus for  
MIG welding.  
13 P8 (Jog/Purge Push Button)  
Performs jog and purge operations.  
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  
1
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  
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4-2. Switching On Unit And Recalling Factory Parameters  
Install power source and wire feeder ac-  
cording to supplied Owner’s Manuals. Turn  
On welding power source.  
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.  
Turn power source Off then On again. Im-  
mediatelypress wire feeder P1 and P3. Re-  
lease P1 and P3 when MEM CLR appears  
on D1 and D2. Turn power source Off when  
DON appears on D1. All parameters will re-  
turn to factory default settings the next time  
unit is turned on.  
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.  
To recall factory-set parameters:  
. Write down any parameters that need  
to be restored before performing this  
procedure.  
When Stick or TIG welding the wire feeder  
is energized but does not work. Displays  
4-3. Welding Process Selection  
L6  
L7  
L8  
L9  
MIG welding selection is made on the pow-  
er source. Wire Feeder shows the welding  
process selected with four LED’s.  
5.0 T to 5.0 T).  
Transfer). Both MIG processes pro-  
vide a stable arc and minimum spatter.  
D2 value is wire feed speed (from min to  
max value according to welding curve  
selection).  
L8 selection is Synergic Pulsed MIG weld-  
ing. See Section 4-12.  
D1 value is Trim, default is 0.0 (range is  
5.0 to 5.0).  
Values and parameters that appear on D1  
and D2 are either factory default settings or  
last settings entered for the selected pro-  
cess.  
. 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 weld-  
ing with the same parameter combina-  
tion 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  
D2 value is wire feed speed (from minimum  
to maximum value according to welding  
curve selection).  
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).  
L9 selection is Synergic Double Pulsed  
D1 value is trim, default is 0.0 (range is 5  
to 5).  
L2 selection is Synergic MIG welding (non-  
pulsed). See Section 4-10.  
D2 value is wire feed speed (from min to  
max value according to welding curve  
selection).  
D1 value is trim, default is 0.0 T (range is  
OM-223 839 Page 12  
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4-4. Trigger Mode Selection  
L10  
L11  
L12  
P1  
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 pressed a second time,  
welding continues at level 2 parameters.  
. Always check and set a trigger mode.  
If trigger mode is undefined for a weld-  
ing process, select the desired mode.  
When trigger is released the second time,  
welding stops.  
L12 trigger mode is useful for aluminum  
and for a crater fill sequence.  
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, Syn-  
ergic MIG, Synergic Pulsed MIG, and Syn-  
ergic Double Pulsed MIG welding, press-  
ing P1 will change trigger mode, but D1 and  
D2 will not change values.  
When trigger is released, welding contin-  
ues.  
In Manual MIG process, 2 times and 4  
times trigger mode can be selected.  
When trigger is pressed and released a  
second time, welding stops.  
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.  
L12 ON selects 3 levels trigger function.  
When trigger is pressed, welding starts  
with level 1 parameters.  
Press P1 to select the desired trigger  
mode:  
In Synergic Double Pulsed MIG process, 2  
times, 4 times, and 3 levels can be se-  
lected.  
When trigger is released, welding contin-  
ues with main parameters.  
L10 ON selects 2 times trigger function.  
4-5. Setup Menu and Memory Menu Selection  
L13 and L14 are generally OFF.  
P2 selects the Setup Menu and the ad-  
vance programming of MIG welding and to  
memorize and manage personal welding  
parametersin MIG welding.  
L13  
L14  
P2  
Press P2 to select Setup Menu. L13 is ON.  
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 er-  
rors in the welding parameters and in  
the memorized welding parameters.  
OM-223 839 Page 13  
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4-6. Setup Menu  
Press P2 to enter SET UP menu.  
Use E1 to select SET (setup) SHO (short)  
on D1 and D2 (default setting).  
. Incorrect settings in any process can  
Setup allows viewing and changing default  
parametervalues 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.  
result in a program with undesirable  
weld characteristics. Setup should  
only be used by operators familiar with  
various welding processes and pa-  
rameters.  
Use E2 to change D2 to FULL.  
. MENU SHORT only shows basic pa-  
rameters for welding processes. SET-  
UP FULL shows all parameters for  
welding processes. Menu selection is  
set when exiting the Setup Menu.  
Setting Menu Type  
P2 allows to exit setup Menu and Ad-  
vanced Programming and to save the  
changed parameters.  
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 se-  
lected 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.  
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 posi-  
tion.  
When D2 shows dEL (delete), you can de-  
lete 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 weld-  
er exits the Memory menu.  
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  
memorizethe actual welding parameters in  
the memory position selected by D1.  
. Do not perform any operation on the  
welder when in Memory menu to pre-  
vent incorrect weld parameters and  
poor operation.  
Verify the Power Source status before  
welding, if needed.  
4-8. Jog And Purge Selection  
L15  
L16  
P3  
Jog feeds welding wire without weld output  
power applied to the wire.  
When L16 illuminates, press and hold P3 to  
perform purge function.  
. If a function is selected and not used  
within several seconds, the LED will  
turn off .  
In Jog mode, D1 shows JOG and D2  
shows wire feed speed.  
. Purge is used to remove impurities and  
To use the jog and purge function, proceed  
as follows:  
fill the gas hose with shielding gas.  
PreGas 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.  
Use E2 to change wire feed speed setting.  
Pressing P3 once selects jog. Pressing P8  
a second time selects purge.  
. Jog will be performed if gun trigger is  
pressed and held without striking a  
welding arc. Front panel Jog is recom-  
mended.  
When L15 illuminates, press and hold P3 to  
perform jog function.  
OM-223 839 Page 14  
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4-9. Preparing Unit For MIG Welding  
To select MIG welding process, pro-  
ceed as follows:  
Follow safety precautions according to  
1
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.  
4
2
If using a water-cooled gun,  
connect input coolant hose to blue  
quick connect fitting  
2
3
3
Connect return coolant hose to  
red quick connect fitting.  
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.  
Allow time for unit to complete its start  
up cycle.  
1
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  
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4-10. Selecting Manual MIG Welding  
E1  
D1  
D2  
E2  
L3  
L4  
L1  
L6  
P1  
P2  
Set Manual MIG welding process on the power source. L6 is On.  
tance setting produces a stiffer weld puddle and more spatter,  
but arc starts may be easier.  
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.  
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.  
Use E2 to change wire feed speed.  
D2 value is default setting of 0.0 s (range is 0.0 s to 10.0 s).  
Use E2 to change D2 value.  
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.  
If necessary, use P2 to adjust the welding parameters.  
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.  
Setting Inductance  
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.  
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%).  
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.  
. Higher inductance setting produces a softer weld puddle and  
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.  
less spatter, but arc starts may be more difficult. Lower induc-  
OM-223 839 Page 16  
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4-11. Selecting Synergic MIG Welding  
E1  
D1  
D2  
E2  
L7  
P1  
P2  
P3  
L1  
L2  
L3  
L4  
L5  
Set Synergic MIG welding process on the  
power source. L7 is ON.  
Setting Trim  
Setting Inductance  
D1 value is default trim setting of 0.0 T  
(range is 5.0 T to 5.0 T).  
Press P2 to enter SET UP menu.  
Use E1 to select on D1 ind. D2 shows 100.  
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 auto-  
matically sets appropriate weld voltage.  
Synergic welding also sets many secon-  
dary welding parameters automatically for  
improved weld quality.  
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 Set-  
tings  
To change all values list, unit must be SET-  
UP FULL. To set unit to SETUP FULL, pro-  
ceed as follows:  
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.  
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).  
Wire Feed Speed Unit (only in SETUP  
FULL)  
Press P2 to enter SET UP menu.  
D2 value is default wire feed speed setting  
of 5.0 m/min (minimum (MIN), maximum  
(MAX), or default (DEF) values are arbi-  
trary based on set welding data). Use P2  
and E2 to change this display to amperes  
or to the thickness of the material.  
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 regu-  
lation is the welding current in Amperes. L4  
is ON.  
When D2 shows thc (thickness) the main  
regulationis the material thickness in mm.  
L5 is ON.  
See Section 4-10.  
Setting PreGas (only in SETUP FULL)  
See Section 4-10.  
Setting Post-Gas (only in SETUP FULL)  
See Section 4-10.  
While Setting Parameters:  
Setting Burnback (only in SETUP FULL)  
See Section 4-10.  
- L2 ON means that D1 shows Trim value.  
- L3 ON means that D2 shows the wire  
speed in meter/min or inch/min.  
Setting Run-In (only in SETUP FULL)  
See Section 4-10.  
- L4 ON means that D2 shows the set weld-  
ing current in amperes.  
Setting 3 Level Trigger Mode (only in  
SETUP FULL)  
- L5 ON means that D2 shows the thick-  
ness of material to weld.  
While Welding:  
Use E1 to change D1 to 3L.1  
D2 value is the default setting of 130%  
(range is 20% to 200%).  
- D1 shows the measured welding voltage  
in Volts. L1 is ON.  
. The modification to the main welding  
regulation is confirmed when exiting  
the Set Up Menu.  
Use E2 to change D2 value.  
Use E1 to change D1 to 3L.2  
- 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).  
. The measured welding current can be  
differentfrom the set value. This differ-  
ence 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.  
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).  
If necessary, use P2 to adjust the welding  
parameters.  
. Material thickness setting is a refer-  
Purge air from gun hose using P3 pushbut-  
This value is the ramp time in seconds to  
reach the following level wire speed.  
ence value only.  
OM-223 839 Page 17  
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4-12. Selecting Synergic Pulsed MIG Welding  
E1  
D1  
D2  
E2  
L7  
L8  
P1  
P2  
P3  
L1  
Set Synergic Pulsed MIG welding process on the To change all values list, unit must be SETUP Some metals weld better using the Synergic  
L2  
L3  
L4 L5  
power source. L7 is On.  
FULL. To set unit to SETUP FULL, proceed as Pulsed Welding process due to the unique puls-  
follows:  
ing of the welding arc. Heat generated in the  
workpiece is generally lower and the arc charac-  
teristics produce a better weld bead appearance  
especially on aluminum. The Synergic Double  
Pulsed MIG process allows control all parame-  
ters to produce high quality welds on aluminum.  
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 ad-  
just welding data (wire type, wire diameter, and  
gas type) and only one weld parameter. General-  
ly, wire feed speed is adjusted and the synergic  
process automatically sets appropriate weld  
voltage. Synergic welding also sets many sec-  
ondary welding parameters automatically for im-  
proved weld quality.  
Press P2 to enter SET UP menu.  
Select SETUP FULL on D1 and D2 (see Section  
4-6).  
Setting Main Welding Regulation  
. Incorrect settings in Synergic Double  
Setting Inductance in Synergic Pulsed MIG  
Welding  
Pulsed Welding process can result in a pro-  
gram with undesirable weld characteristics.  
Setup should only be used by operators fa-  
miliar with various welding processes and  
parameters. In some cases, standard Syn-  
ergic Pulsed MIG welding can produce bet-  
ter welds.  
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.  
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 de-  
fault (DEF) values are arbitrary based on set  
welding data). Use P2 and E2 to change this dis-  
play to amperes or to the thickness of the weld.  
Press P2 to enter SET UP menu.  
Use E1 to change D1 to 2P.F.  
Use E2 to change D2 value.  
. Change these parameters as little as pos-  
sible because the factory settings are pre-  
ferred for most applications.  
Big changes can affect the arc stability and  
weld performance.  
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.  
In general, remain in the 70% to 130%  
range.  
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 See Section 4-10.  
material to weld.  
Use E1 to change D1 to 2P.C.  
D2 value is default setting of 50%.  
Use E2 to change D2 value.  
Wire Feed Speed Unit (only in SETUP FULL)  
Setting Pre-Gas (only in SETUP FULL)  
The range of this setting is 25% to 75%. This set-  
ting allows changing the time that the pulse is at  
high output. A lower setting will produce less  
heating at the welding puddle.  
Setting Post-Gas (only in SETUP FULL)  
While Welding:  
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 be-  
tween 4 m/min and 6 m/min. A recommended  
setting is 20%.  
- D1 shows the measured welding voltage in  
Volts. L1 is ON.  
- D2 shows the measured welding current in am-  
peres. L4 is ON.  
Set wire speed, welding current or material thick-  
ness 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 pa-  
rameters.  
Purge air from gun hose using P3 pushbutton  
(see Section 4-8).  
Setting Burnback (only in SETUP FULL)  
Setting Run-In (only in SETUP FULL)  
Setting 3 Level Trigger Mode  
Setting Synergic Double Pulsed MIG  
Use E1 to change D1 to 2P.A. D2 value is the de-  
fault setting of 0.0. Use E2 to change D2 value.  
. Synergic Double Pulsed MIG process is se-  
lected at the power source or recalled in the The range of this setting is 5.0 to 5.0.  
wire feeder using Synergic Double Pulsed This setting allows changing the low end of trim  
programs. All Double Pulse parameters are in double pulse and the main setting for trim will  
selected on the wire feeder. All other MIG be the low end. A higher 2P.A setting will produce  
parameters are the same as standard a longer and hotter arc and lower setting will pro-  
Setting Trim  
Synergic Pulsed MIG Welding Advanced Set-  
tings  
Pulsed MIG process.  
duce a shorter and cooler arc.  
OM-223 839 Page 18  
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SECTION 5 MAINTENANCE & TROUBLESHOOTING  
5-1. Routine Maintenance  
Y
Disconnect power  
before maintaining.  
. Maintain more often  
during severe conditions.  
3 Months  
Clean And  
Replace  
Damaged Or  
Unreadable  
Labels  
Tighten  
Weld  
Replace Damaged  
Gas Hose  
Terminals  
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 Verify that the motor and cabling are functioning.  
units.  
HLP 104  
In case of failure, D1 and D2 will show the following Error Signals.  
HLP 100  
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 en-  
coder.  
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 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 101  
Indicates that the current in the motor is too high.  
Verify that the wire has not stopped.  
HLP 102  
HLP 106  
Indicates that the voltage on the motor is too high.  
Verify that the wire has not stopped.  
HLP 103  
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.  
Indicates that there is a short circuit in the motor or in the cabling.  
OM-223 839 Page 19  
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5-3. Troubleshooting  
Problem  
Solution  
Check continuity of Power switch S1, and replace if necessary.  
Reset circuit breaker CB1 if open.  
Unit is completely inoperative.  
Check input power source. See welding power source Technical Manual.  
Turn Power switch On.  
Wire does not feed, unit completely inop-  
erative.  
Check 14pin 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.  
Readjust hub tension and drive roll pressure.  
Use correct size drive roll (see Parts List).  
Clean or replace dirty or worn drive roll.  
Wire feeds erratically.  
Remove weld spatter around nozzle opening.  
Replace contact tip or liner. See gun Owner’s Manual.  
Check wiring between Motor Board and Encoder  
Realign drive rolls.  
Electrode wire feeding stops or feeds  
erratically during welding.  
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.  
Check coil voltage and connections of gas valve. Check continuity of coil. Replace if necessary.  
Check continuity of Purge switch, and replace if necessary.  
Recall factory parameters as explained in this manual.  
Call a Factory Authorized Service Agent.  
Wire feeds, but gas does not flow with  
gun trigger pressed.  
Software or visualization problems.  
Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace if necessary.  
Clear blockage in gas hose or replace hose.  
Wire feeds and electrode wire is ener-  
gized, but gas flow is irregular.  
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.  
Recall factory parameters as explained in this manual.  
OM-223 839 Page 20  
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SECTION 6 ELECTRICAL DIAGRAM  
May 9, 2005  
OM-223 839 Page 21  
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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
6
1
5
17  
20  
21  
22  
18  
19  
33  
32  
23  
24  
31  
25  
30  
29  
26  
28 27  
.
May 9, 2005  
Figure 7-1. Main Assembly  
OM-223 839 Page 22  
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Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
. . . 1 . . . . . . . . . . . . . . . . . . V57052030 . . . Euro adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . . . . . . . . . . . . . . . . 028066243 . . . Wire drive system with encoder motor . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . . . . . . . . . . . . . . . . . . V56014178 . . . Board protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 4 . . . . . . . . . . . . . . . . . . . 000178937 . . . Label, warning, gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 5 . . . . . . PC2 . . . . . . . V57084045 . . . Circuit board, motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 6 . . . . . . CB1 . . . . . . . . 000083432 . . . Circuit breaker, 10 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 7 . . . . . . . . . . . . . . . . . . . 000151187 . . . Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 8 . . . . . . . . . . . . . . . . . . V16122177 . . . Panel, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . . . . . . . . . . . . . . 000178936A . . . Label, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . . . . . . . . . . . . . . . . . . . 000206108 . . . Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 11 . . . . . . . . . . . . . . . . . . . 156034004 . . . Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 12 . . . . . . . . . . . . . . . . . +V16121130 . . . Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 13 . . . . . . . . . . . . . . . . . . V56161034 . . . Reel, holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . . . . . . . . . . . . . . . V56031169 . . . Baffle, intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . . . . . . . . . . . . . . +V16118172 . . . Panel, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 16 . . . . . . . . . . . . . . . . . +V57060135 . . . Baffle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 17 . . . . . . . . . . . . . . . . . . V56079197 . . . Collar, stauff din 1593 15.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . . . . . . . . 000204326 . . . Tool tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 19 . . . . . . . . . . . . . . . . . . V16122168 . . . Panel, side rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 20 . . . . . . . . . . . . . . . . . . V27028202 . . . Kit, receptacle, 14 pin M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 21 . . . . . . . . . . . . . . . . . . . 056076216 . . . Power connector M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 22 . . . . . . ELV . . . . . . . . 056061042 . . . Valve, solenoid, 24 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 23 . . . . . . . . . . . . . . . . . . . 556049372 . . . Connector, coupling, blue fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 24 . . . . . . . . . . . . . . . . . . . 556049373 . . . Connector, coupling, red fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 25 . . . . . . . . . . . . . . . . . . V16118129 . . . Panel, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 26 . . . . . . . . . . . . . . . . . +V17026131 . . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 27 . . . . . . . . . . . . . . . . . . V57094063 . . . Kit, receptacle, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 28 . . . . . . . . . . . . . . . . . . . 556049368 . . . Connector, coupling, blue fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 29 . . . . . . . . . . . . . . . . . . . 556049369 . . . Connector, coupling, red fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 30 . . . . . . . . . . . . . . . . . . V16029155 . . . Panel, front, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 31 . . . . . . . . . . . . . . . . . . . 756005024 . . . Flange, euro adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 32 . . . . . . PC1 . . . . . . . V57084166 . . . Circuit board, control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 33 . . . . . . . . . . . . . . . . . . . 000193919 . . . Knob, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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  
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. Hardware is common and  
not available unless listed.  
24  
25  
23  
22  
21  
20  
19  
18  
1
2
4
17  
3
4
5
16  
6
15  
14  
7
8
9
10  
11  
12  
13  
May 9, 2005  
Figure 7-2. Wire Drive Assembly  
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
. . . 1 . . . . . . . M . . . . . . . . . 057010052 . . . Motor, 24 VDC, 60 W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . . . . . . . . . . . . . . . . 000601966 . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . . . . . . . . . . . . . . . . . . . 156018021 . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 4 . . . . . . . . . . . . . . . . . . . 000602213 . . . Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 5 . . . . . . . . . . . . . . . . . . . 656005026 . . . Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 6 . . . . . . . . . . . . . . . . . . . 000604673 . . . Screw, hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 7 . . . . . . . . . . . . . . . . . . . 000187325 . . . Insulator, drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . . . . . . . . . . . . . . . . . 000166338 . . . Lever, mounting pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . . . . . . . . . . . . . . . . 000166337 . . . Housing adapter gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . . . . . . . . . . . . . . . . . . . 000072010 . . . Bushing, insulating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 11 . . . . . . . . . . . . . . . . . . . 000108943 . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 12 . . . . . . . . . . . . . . . . . . . 000173618 . . . Carrier, drive roll, keyed, 24 pitch . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 13 . . . . . . . . . . . . . . . . . . . 000602239 . . . Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . . . . . . . . . . . . . . . . 000174609 . . . Screw, .250-20 x .500 soc hd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . . . . . . . . . . . . . . . . 000602009 . . . Screw, .250-20 x 1.250 soc hd hex gr 8 . . . . . . . . . . . . . . . . . . . . 4  
. . . 16 . . . . . . . . . . . . . . . . . . . 000172075 . . . Carrier, drive roll, with component, 24 pitch . . . . . . . . . . . . . . . . . 4  
. . . 17 . . . . . . . . . . . . . . . . . . . 000601872 . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . . . . . . . . 000602213 . . . Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 19 . . . . . . . . . . . . . . . . . . . 000010224 . . . Pin, spring CS .187 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 20 . . . . . . . . . . . . . . . . . . . 000166071 . . . Lever, mounting pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 21 . . . . . . . . . . . . . . . . . . . 000089562 . . . Fastener, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 22 . . . . . . . . . . . . . . . . . . . 000085244 . . . Washer, cupped stl, .328 ID x .812 OD x .125 . . . . . . . . . . . . . . . 2  
. . . 23 . . . . . . . . . . . . . . . . . . . 000089477 . . . Spring, cprsn .770 OD x .105 wire x 1.225 . . . . . . . . . . . . . . . . . . 2  
. . . 24 . . . . . . . . . . . . . . . . . . . . 00089243 . . . Knob, tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 25 . . . . . . . . . . . . . . . . . . . 000202562 . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
OM-223 839 Page 24  
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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.  
NOTE  
5. Drive roll types may be mixed to suit particular requirements (example:  
V-Knurled roll in combination with U-Grooved).  
Wire Diameter  
Fraction  
Drive Roll  
Type  
Wire Guide  
Inlet  
Kit No.  
Metric  
0.6 mm  
0.8 mm  
0.9 mm  
1.0/1.2 mm  
1.0 mm  
1.2 mm  
1.6 mm  
0.9 mm  
1.2 mm  
1.3 mm  
1.6 mm  
2.0 mm  
0.9 mm  
1.2 mm  
1.3 mm  
1.6 mm  
1.8 mm  
2.0 mm  
1.2 mm  
1.3 mm  
1.6 mm  
2.0 mm  
Decimal  
0.023/0.025 in  
0.030 in  
Part No.  
087 130  
053 695  
053 700  
189 285  
053 696  
053 697  
053 699  
072 000  
053 701  
053 702  
053 706  
053 704  
132 958  
132 957  
132 956  
132 955  
132 959  
132 960  
083 489  
083 490  
053 708  
053 710  
Intermediate  
056 206  
056 206  
056 206  
056 207  
056 206  
056 207  
056 209  
056 206  
056 207  
056 207  
056 209  
056 209  
056 206  
056 207  
056 207  
056 209  
056 209  
056 209  
056 207  
056 207  
056 209  
056 209  
0.023/0.025 in  
0.030 in  
0.035 in  
0.035/0.045 in  
0.040 in  
0.045 in  
1/16 in  
087 132  
046 780  
046 781  
N/A  
V-Grooved  
V-Grooved  
V-Grooved  
V-Grooved  
V-Grooved  
V-Grooved  
V-Grooved  
U-Grooved  
U-Grooved  
U-Grooved  
U-Grooved  
U-Grooved  
V-Knurled  
V-Knurled  
V-Knurled  
V-Knurled  
V-Knurled  
V-Knurled  
U-Cogged  
U-Cogged  
U-Cogged  
U-Cogged  
056 192  
056 192  
056 192  
156 193  
056 192  
056 193  
056 195  
056 192  
056 193  
056 193  
056 195  
056 195  
056 192  
056 193  
056 193  
056 195  
056 195  
056 195  
056 193  
056 193  
056 195  
056 195  
0.035 in  
0.035/0.045 in  
0.040 in  
191 917  
046 782  
046 784  
044 750  
046 785  
046 786  
046 787  
046 788  
046 782  
046 793  
046 794  
046 795  
089 985  
046 796  
083 319  
083 320  
046 800  
046 801  
0.045 in  
0.062 in  
0.035 in  
0.045 in  
0.052 in  
1/16 in  
0.035 in  
0.045 in  
0.052 in  
0.062 in  
5/64 in  
0.079 in  
0.035 in  
0.045 in  
0.052 in  
1/16 in  
0.035 in  
0.045 in  
0.052 in  
0.062 in  
0.068-0.072 in  
5/64 in  
0.068-0.072 in  
0.079 in  
0.045 in  
0.052 in  
1/16 in  
0.045 in  
0.052 in  
0.062 in  
5/64 in  
0.079 in  
OM-223 839 Page 25  
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Notes  
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Effective January 1, 2006  
This limited warranty supersedes all previous Miller warranties and is exclusive with no other  
guarantees or warranties expressed or implied.  
LIMITED WARRANTY Subject to the terms and conditions  
below, ITW Welding Products Italy S.r.l., 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.  
*
*
*
*
*
*
APT Model Plasma Cutting Torches  
Remote Controls  
Accessory Kits  
Replacement Parts (No labor)  
Spoolmate Spoolguns  
Canvas covers  
Miller’s True Blue® Limited Warranty shall not apply to:  
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.  
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.  
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 that  
the equipment was delivered to the original retail purchaser,  
or one year after the equipment is sent to a European  
distributor or eighteen months after the equipment is sent to  
an International distributor.  
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.  
1. 5 Years Parts 3 Years Labor  
*
*
Original main power rectifiers  
Inverters (input and output rectifiers only)  
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.  
2. 3 Years — Parts and Labor  
*
*
*
*
*
*
*
*
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)  
Intellitig  
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.  
Maxstar 150  
Engine Driven Welding Generators  
(NOTE: Engines are warranted separately by the  
engine manufacturer.)  
3. 2 year Parts and Labor (Panther only)  
Hydramate 1&2 Water Cooling Unit  
4. 1 year Parts and Labor unless specified  
*
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.  
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DC 253 & 403 Rectifier (April 06>)  
Migmatic 171 (April 06>)  
Motor Driven Guns (w/exception of Spoolguns)  
Process Controllers  
Positioners and Controllers  
Automatic Motion Devices  
RFCS Foot Controls  
IHPS Power Sources and Coolers  
Water Coolant Systems (nonintegrated)  
Flowgauge and Flowmeter Regulators (No Labor)  
HF Units  
Grids  
Spot Welders  
Load Banks  
Arc Stud power sources and Arc Stud guns  
Running Gear/Trailers  
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.  
Some states in the U.S.A. do not allow limitations of how long  
an implied warranty lasts, or the exclusion of incidental,  
indirect, special or consequential damages, so the above  
limitation or exclusion may not apply to you. This warranty  
provides specific legal rights, and other rights may be  
available, but may vary from state to state.  
Plasma Cutting Torches (except APT  
Models)  
&
SAF  
*
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.)  
In Canada, legislation in some provinces provides for certain  
additional warranties or remedies other than as stated  
herein, and to the extent that they may not be waived, the  
limitations and exclusions set out above may not apply. This  
Limited Warranty provides specific legal rights, and other  
rights may be available, but may vary from province to  
province.  
5
6 Months — Batteries  
6. 90 Days — Parts  
*
*
MIG Guns/TIG Torches  
Induction heating coils and blankets  
milan_warr 1/06  
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Owner’s Record  
Please complete and retain with your personal records.  
Model Name  
Purchase Date  
Distributor  
Address  
Serial/Style Number  
(Date which equipment was delivered to original customer.)  
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.  
Via Privata Iseo, 6/E  
20098 San Giuliano  
Milanese, Italy  
Phone: 39 (0) 2982901  
Fax: 39 (0) 298290-203  
email: miller@itwwelding.it  
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  
© 2006 Miller Electric Mfg. Co. 1/06  
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