OM-223 839B
2006−07
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
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. Manufacturer’s Rating Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-9. Installing Wheels On Wire Feeder (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-1. Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-2. Switching On Unit And Recalling Factory Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-3. Welding Process Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-4. Trigger Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-5. Setup Menu and Memory Menu Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-6. Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-7. Memory Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-8. Jog And Purge Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-9. Preparing Unit For MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-10. Selecting Manual MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-11. Selecting Synergic MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-12. Selecting Synergic Pulsed MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 5 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-2. Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 6 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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
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.
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D
Y
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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.
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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.
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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.
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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.
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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.
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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).
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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.
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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.
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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.
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Wear approved safety glasses with side shields under your
helmet.
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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
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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.
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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.
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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.
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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.
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Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
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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.
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Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
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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.
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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.
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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.
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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.
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Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
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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.
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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.
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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
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Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
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Do not block or filter airflow to unit.
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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.
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Have the installation regularly checked and maintained.
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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.
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Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
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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:
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 10036−8002 (phone: 212−642−4900,
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 02269−9101 (phone:
617−770−3000,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
02269−9101(phone: 617−770−3000, 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 22202−4102 (phone: 703−412−0900, 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
312−353−2220,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
committee’s 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
1−2
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-
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
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-
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.
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.
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
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
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.
Setting Pre−Gas (only in SETUP FULL)
Setting Post-Gas (only in SETUP FULL)
While Setting Parameters:
Setting Burnback (only in SETUP FULL)
- 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)
- 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
. 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.
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
If necessary, use P2 to adjust the welding pa-
rameters.
Purge air from gun hose using P3 pushbutton
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 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.
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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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 (non−integrated)
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@itw−welding.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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