Miller XMS 44 User Manual

OM-223 839B

2006−07

Processes

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Description

Wire Feeder

XMS 44

Wire Feeder

OWNER’S MANUAL

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the
job done and get it done right. We know you don’t have time to do it any
other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior quality.
Like you, his customers couldn’t afford anything less. Miller products had
to be more than the best they could be. They had to be the best you could
buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller Electric manufactures a full line of
welders and welding related equipment.
For information on other quality Miller products, contact your local
Miller distributor to receive the latest full line catalog or individual
specification sheets.

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − DEFINITIONS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Manufacturer’s Warning Label Definitions 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Manufacturer’s Rating Labels 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Symbols And Definitions 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INTRODUCTION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Remote 7 Receptacle Information 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. 14-Pin Plug Information 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Connecting Welding Gun 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Installing Wire Guide And Drive Roll 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Circuit Protection 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Connecting Wire Feeder to Power Source 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Declaration of Conformity for

European Community (CE) Products

NOTE

Manufacturer: European Contact:

ITW Welding Products Italy S.r.l. Mr. Danilo Fedolfi,
Via dell’Industria, 55 Managing Director
36030 Sarcedo ITW Welding Products Italy S.r.l.
Vincenza, Italy Via Privata Iseo 6/E
Phone: [phone] 20098 San Giuliano

European Contact Signature:

Declares that this product: XMS 44

conforms to the following Directives and Standards:

This information is provided for units with CE certification (see rating label on unit).

Milanese, Italy
Phone: [phone]
Fax: [phone]

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

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

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.

som _3/05

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.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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

live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work
or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on

unit.

D Additional safety precautions are required when any of the 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 unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

power circuit and machine internal circuits are also

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.

D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section
before touching any parts.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.

D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch­person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath­ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

OM-223 839 Page 1

ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

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).

D Wear approved safety glasses with side shields under your

helmet.

D 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.

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

burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see
Safety Standards).

D 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 Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

workpiece, and hot equipment can cause fires and

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.

D Wear approved safety glasses with side

shields even under your welding helmet.

D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or

torch.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.
D Wearers should consult their doctor before

going near arc welding, gouging, or spot
welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D Wear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and
associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

OM-223 839 Page 2

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of
unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors,

panels, covers, or guards for maintenance as
necessary.

D Reinstall doors, panels, covers, or guards

when maintenance is finished and before re­connecting input power.

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
communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa­tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.
D 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.

MOVING PARTS can cause injury.

D Keep away from moving parts.
D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading
welding wire.

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.)

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
reproductive harm. Wash hands after handling.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D 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.

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 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

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard

AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, P.O. Box 9101, 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, web­site: www.cganet.com).

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

Welding current, as it flows through welding cables, will cause electro­magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power­frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

To reduce magnetic fields in the workplace, use the following
procedures:

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-
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).

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).

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220, website: www.osha.gov).

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.

4. Keep welding power source and cables as far away from opera­tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi­ble.

About 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.

OM-223 839 Page 4

SECTION 2 − DEFINITIONS

2-1. Manufacturer’s Warning Label Definitions

ABC

1 1.1 1.2 1.3

2

3 3.1 3.2 3.3

4 4.1

56

2.1

+

2.2

+

2.3

+

+

S-178 936

1. Warning! Watch Out! There are
possible hazards as shown by the
symbols.

2. Drive rolls can injure fingers

3. Welding wire and drive parts are at
welding voltage during operation −
keep hands and metal objects clear.

1 Electric shock can kill.

1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.

1.2 Protect yourself from electric shock by
insulating yourself from work and
ground.

1.3 Disconnect input plug or power before
working on machine.

2 Breathing welding fumes can be

hazardous to your health.

2.1 Keep your head out of the fumes.

2.2 Use forced ventilation or local exhaust
to remove the fumes.

2.3 Use ventilating fan to remove fumes.

3 Welding sparks can cause explosion

or fire.

3.1 Keep flammables away from welding.
Don’t weld near flammables.

3.2 Welding sparks can cause fires. Have
a fire extinguisher nearby and have a
watch person ready to use it.

3.3 Do not weld on drums or any closed
containers.

4 Arc rays can burn eyes and injure

skin.

4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.

5 Become trained and read the

instructions before working on the
machine or welding.

6 Do not remove or paint over (cover)

the label.

Do not discard this product with
general waste.

Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collec­tion facility.

Contact your local recycling office
or your local distributor for further
information.

OM-223 839 Page 5

2 3

2-2. Manufacturer’s Rating Labels

1

1 Warning! Watch Out! There

are possible hazards as

shown by the symbols.
2 Drive rolls can injure fingers
3 Welding wire and drive parts

are at welding voltage during

operation − keep hands and

metal objects away.

2-3. Symbols And Definitions

NOTE

A

IP

U

2

On Off Input Output

Amperes

Degree Of
Protection

Read Instructions

Purge Remote

Conventional
Load Voltage

Symbols found on product.

V

Hz

U

1

I

1

Volts Alternating Current

Hertz Circuit Breaker Wire Feed

Primary Voltage

Primary Current

. Symbols not shown here are detailed in this manual when they are relevant.

X

Gas Metal Arc

Welding (GMAW)

Water (Coolant)

Input

I

2

Rated Welding

Current

Duty Cycle

Line Connection

Water (Coolant)

Output

OM-223 839 Page 6

3-1. Specifications

A

J

K

A

J

K

EFE

F

SECTION 3 − INTRODUCTION

Type of Input

Power

24 Volts AC

Single-Phase

7 Amperes

50/60 Hertz

Welding Power

Source Type

XMS 4000 Welding Power

Source

Wire Feed

Speed Range

0.5 − 20 m/min

3-2. Remote 7 Receptacle Information

Welding

Wire Diameter Range

0.8 mm − 1.8 mm

Max Spool Weight:

15 kg

Pin Pin Information

1 +10 volts DC supply voltage to remote control

2 GND Remote control circuit common

3 IREF 0 to 10 current control signal

4 VREF 0 to 10 voltage control signal

5 UP 0V/10V digital signal

Circuit
Rating

36 Volts,

400
Amperes,
30% Duty

Cycle

Length: 640 mm

Width: 225 mm

Height: 435 mm

Overall

Dimensions

Weight

23 kg

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 24 volts AC with respect to socket G. Protected by circuit breaker CB1.
B GND of communciation signals.

J

IBI

H

H

G

*The remaining pins are not used.

AJA

B

CLN

DM DM

E

E

C Serial communciation signal −485.
D Serial communication signal +485.
E Start motor signal to XMS 44.
F Trigger switch signal to XMS 4000.
G Circuit common for 24 volts AC circuit.
H Wire feeder speed signal to XMS 44.

OM-223 839 Page 7

3-4. Connecting Welding Gun

1

1 Gun Securing Knob
2 Gun Block
3 Gun Outlet Wire Guide
Loosen knob, insert gun into block.

Position outlet wire guide as close
as possible to drive rolls without

2

3

US Gun

touching. Tighten knob.
4 Gun Trigger Plug
5 Gun Trigger Receptacle

. Contact manufacturer for

equipment needed to connect
US Gun.

. Make cooling system connec-

4

5

1

2

Gun

Euro

tions as shown in Section 3-7.

3-5. Installing Wire Guide And Drive Roll

1

3

2

Tools Needed:

3/8 in

1−2

3

Correct Alignment

Incorrect Alignment

802 308

1 Inlet Wire Guide
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.

Aligning Wire Guide And Drive
Rolls:

View is from top of drive rolls
looking down with pressure assem­bly open.

Turn screw in or out until drive roll
groove lines up with wire guide.

Close pressure roll assembly.
Repeat for remaining drive rolls un-

til all drive rolls line up with wire
guides as shown.

802 310-A

OM-223 839 Page 8

3-6. Circuit Protection

1

3-7. Connecting Wire Feeder to Power Source

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
2

3
4

7

6

5

5

4

1

2

Make connections as shown. Be
sure connections are tight.

1 14 Pin Control Cord
2 Weld Cable (see Section 3-8

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.

4 Blue Quick Connect Fitting

(Coolant Output to Gun)
Connect blue to blue and red to red.
5 Red Quick Connect Fitting

(Coolant Return From Gun)
Connect blue to blue and red to red.
6 Work Cable Clamp (see

Section 3-8)
7 Cable Bundle Collar (see

Section 3-8)

OM-223 839 Page 9

3-8. Changing Cable Between Wire Feeder and XMS 4000

3

2

3

1

Y Disconnect power before

changing cables.

1 Access Door
2 Clamp
3 Plastic Collar
Connect weld cable to terminals be-

hind access door.
Remove screws securing door,

clamp and collar. Make cable con­nections. Reinstall clamp, collar,
and door.

Tools Needed:

3-9. Installing Wheels On Wire Feeder (Optional)

1

3

1 Wheels
2 Bars
3 Screws
Remove rubber feet from wire feeder.

Install only wheels on feeder if smaller
dimensions are desired, unit will be
used on level floors, or if optional turn­table is used.

Install wheels and bars for increased
stability on uneven floors.

Tools Needed:

OM-223 839 Page 10

1

4-1. Control Panel

9

15
14

19
20
21

22

23

24

25

SECTION 4 − OPERATION

1 MIG Gun Connector

587

16 17 18

28

29

4

26

12 13

27

11

3

2

1

2 Red Quick Connect Fitting (Coolant

Return From Gun).

3 Blue Quick Connect Fitting (Coolant

Output To Torch)

4 Remote Control Receptacle

6

5 Handle

10

6 Panel
7 D1 − (Display 1)
Displays values and parameters for selected

welding process.
8 D2 − (Display 2)
Displays values and parameters for selected

welding process.
9 E1 (Encoder Control 1)
Use control to change values and parameters

that appear on D1.
10 E2 (Encoder Control 2)
Use control to change values and parameters

that appear on D2.
11 P1 (Trigger Selection Push Button)
Allows selecting desired trigger mode.
12 P2 (Memory/Setup Push Button)
Allows selecting Memory and Setup menus for

MIG welding.
13 P8 (Jog/Purge Push Button)
Performs jog and purge operations.
14 L1 ON means that D1 shows the voltage

value

15 L2 ON means that D1 shows the Trim

value

16 L3 ON means that D2 shows Wire Speed

value

17 L4 ON means that D2 shows Amperage

value

18 L5 ON means that D2 shows Material

Thickness value
19 L6 selection is Manual MIG welding
20 L7 selection is Synergic MIG welding
21 L8 selection is Synergic Pulsed MIG

welding
22 L9 selection is Synergic Double Pulsed

MIG welding
23 L10 ON selects 2 times trigger function
24 L11 ON selects 4 times trigger function
25 L12 ON selects 3 levels trigger function
26 L13 ON selects Setup menu
27 L14 On selects Memory menu
28 L15 ON selects Jog function
29 L16 ON selects Purge function

OM-223 839 Page 11

4-2. Switching On Unit And Recalling Factory Parameters

Install power source and wire feeder ac­cording to supplied Owner’s Manuals. Turn
On welding power source.

Displays D1 and D2 will show the wire
feeder software version. Welding system is
ready to weld with the factory-set default
values or or the values and parameters of
the last weld.

When Stick or TIG welding the wire feeder
is energized but does not work. Displays

4-3. Welding Process Selection

L6

L7

L8

D1 and D2 will show hyphens. When MIG
welding, wire feeder is always on. Displays
D1 and D2 will show set voltage and wire
speed (or correlated parameters) and the
measured welding voltage and current
while welding.

To recall factory-set parameters:

. Write down any parameters that need

to be restored before performing this
procedure.

Turn power source Off then On again. Im­mediately press wire feeder P1 and P3. Re­lease P1 and P3 when MEM CLR appears
on D1 and D2. Turn power source Off when
DON appears on D1. All parameters will re­turn to factory default settings the next time
unit is turned on.

L9

MIG welding selection is made on the pow­er source. Wire Feeder shows the welding
process selected with four LED’s.

Values and parameters that appear on D1
and D2 are either factory default settings or
last settings entered for the selected pro­cess.

L6 selection is Manual MIG welding. See
Section 4-9.

D1 value is welding voltage; default is 18.5
volts (range is 10 to 50 volts).

D2 value is wire feed speed; default is 5
m/min (range is 1 m/min to 20 m/min).

L2 selection is Synergic MIG welding (non­pulsed). See Section 4-10.

D1 value is trim, default is 0.0 T (range is

−5.0 T to 5.0 T).
D2 value is wire feed speed (from min to

max value according to welding curve
selection).

. When L7 is flashing, material transfer

in the arc is by large droplets (globular
transfer) and produces considerable
spatter. This is the result of selecting a
specific material, wire, gas, voltage,
and current combination. To avoid this
situation, Synergic Pulsed MIG weld­ing with the same parameter combina­tion is recommended. When L7 is On
continuously (not flashing), material
transfer in the arc is either short circuit
(Short Arc) or by small droplets (Spray

Transfer). Both MIG processes pro­vide a stable arc and minimum spatter.

L8 selection is Synergic Pulsed MIG weld­ing. See Section 4-12.

D1 value is Trim, default is 0.0 (range is

−5.0 to 5.0).
D2 value is wire feed speed (from minimum

to maximum value according to welding
curve selection).

L9 selection is Synergic Double Pulsed
MIG welding. See Section 4-12.

D1 value is trim, default is 0.0 (range is −5
to 5).

D2 value is wire feed speed (from min to
max value according to welding curve
selection).

OM-223 839 Page 12

4-4. Trigger Mode Selection

L10

L11

L12

P1

. Always check and set a trigger mode.

If trigger mode is undefined for a weld­ing process, select the desired mode.

Trigger mode can be set for Manual MIG,
Synergic MIG, Synergic Pulsed MIG, and
Synegic Double Pulsed MIG welding to
change when output power is present at
the weld connectors. In Manual MIG, Syn­ergic MIG, Synergic Pulsed MIG, and Syn­ergic Double Pulsed MIG welding, press­ing P1 will change trigger mode, but D1 and
D2 will not change values.

Press P1 to select the desired trigger
mode:

L10 ON selects 2 times trigger function.

When trigger is pressed, welding starts.
When trigger is released, welding stops.
L11 ON selects 4 times trigger function.
When trigger is pressed, welding starts.
When trigger is released, welding contin-

ues.
When trigger is pressed and released a

second time, welding stops.
L12 ON selects 3 levels trigger function.
When trigger is pressed, welding starts

with level 1 parameters.
When trigger is released, welding contin-

ues with main parameters.

4-5. Setup Menu and Memory Menu Selection

L13

L14

P2

When trigger is pressed a second time,
welding continues at level 2 parameters.

When trigger is released the second time,
welding stops.

L12 trigger mode is useful for aluminum
and for a crater fill sequence.

In Manual MIG process, 2 times and 4
times trigger mode can be selected.

In Synergic MIG process, 2 times, 4 times
and 3 levels can be selected.

In Synergic Pulsed MIG process, 2 times,
4 times, and 3 levels can be selected.

In Synergic Double Pulsed MIG process, 2
times, 4 times, and 3 levels can be se­lected.

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
parameters in MIG welding.

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 er­rors in the welding parameters and in
the memorized welding parameters.

OM-223 839 Page 13

4-6. Setup Menu

Press P2 to enter SET UP menu.
Setup allows viewing and changing default

parameter values for all welding processes
for the desired weld characteristics.

D1 shows the welding parameter.
D2 shows the parameter value.
E1 changes the welding parameter.
E2 changes the parameter value.
P2 allows to exit setup Menu and Ad-

vanced Programming and to save the
changed parameters.

4-7. Memory Menu

Press P2 to enter Memory menu.
D1 shows the first free memory position or
the last memory used.
E1 changes the memory position number
from P.01 to P.99.
Any memory position contains all the se­lected MIG welding parameters in the Wire
Feeder and in the Power Source.

When a memorized welding point is loaded
the Wire Feeder and the Power Source is
set accordingly.
Verify the Power Source status before
welding, if needed.

. Incorrect settings in any process can

result in a program with undesirable
weld characteristics. Setup should
only be used by operators familiar with
various welding processes and pa­rameters.

Setting Menu Type

To set menu type, proceed as follows:

Press P2 to enter Setup menu.

D1 shows the memory position.
E1 changes the memory position.
D2 shows the action you can perform on
the memory position.
E2 changes the action on the memory posi­tion.

When D2 shows Ld (load), you can load in
the welder the parameters in the memory
position selected by D1.
When D2 shows Sto (storage), you can
memorize the actual welding parameters in
the memory position selected by D1.

Use E1 to select SET (setup) SHO (short)
on D1 and D2 (default setting).

Use E2 to change D2 to FULL.

. MENU SHORT only shows basic pa-

rameters for welding processes. SET­UP FULL shows all parameters for
welding processes. Menu selection is
set when exiting the Setup Menu.

When D2 shows dEL (delete), you can de­lete the parameters memorized in the
memory position selected by D1.

In order to confirm the action, press P2 until
D1 and D2 flash.
Release P2 and wait until flashing stops.
The action is now performed and the weld­er exits the Memory menu.

. Do not perform any operation on the

welder when in Memory menu to pre­vent incorrect weld parameters and
poor operation.

4-8. Jog And Purge Selection

L15

L16

P3

. If a function is selected and not used

within several seconds, the LED will
turn off .

To use the jog and purge function, proceed
as follows:

Pressing P3 once selects jog. Pressing P8
a second time selects purge.

When L15 illuminates, press and hold P3 to
perform jog function.

OM-223 839 Page 14

Jog feeds welding wire without weld output
power applied to the wire.

In Jog mode, D1 shows JOG and D2
shows wire feed speed.

Use E2 to change wire feed speed setting.

. Jog will be performed if gun trigger is

pressed and held without striking a
welding arc. Front panel Jog is recom­mended.

When L16 illuminates, press and hold P3 to
perform purge function.

. Purge is used to remove impurities and

fill the gas hose with shielding gas.
Pre−Gas is a similar function, but only
operates at the beginning of a welding
process. Purge can be performed in
the TIG process by pressing the torch
trigger without striking an arc.

4-9. Preparing Unit For MIG Welding

1

To select MIG welding process, pro­ceed as follows:

Follow safety precautions according to
Section 1.

Prepare unit according to Section 3.
1 Using a cable with a proper

adapter, connect gun to the MIG
gun connector.

4

2

3

Connect work clamp cable to the
WORK connector on the power source.

2 If using a water-cooled gun,

connect input coolant hose to blue
quick connect fitting

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.
Set MIG welding process on the Power

Source and check L1, L2, L3 and L4 on
the Wire Feeder.

Purge air from the gas hose using P3
pushbutton (see Section 4-8).

OM-223 839 Page 15

4-10. Selecting Manual MIG Welding

E1 D1 D2 E2

L3

L1

L6

P1

P2

Set Manual MIG welding process on the power source. L6 is On.
In Manual MIG mode, the operator may need to adjust main welding

parameters for specific arc characteristics. Wire feed speed and arc
voltage will appear on D1 and D2.

During Setting :

D1 value is default voltage setting of 18.5 V (range is 10 V to 50 V).
L1 is On.

Use E1 to change voltage.
D2 value is default wire feed speed setting of 5.0 m/min (range is 1.0

m/min to 20.0 m/min). L3 is On.
Use E2 to change wire feed speed.

While Welding:

D1 shows the measured welding voltage in volts. L1 is On.
D2 shows the measure welding current in amperes. L4 is On.
Set wire speed and welding voltage with E1 and E2.
Select trigger mode using P1 push button (see Section 4-4).
If necessary, use P2 to adjust the welding parameters.
Purge air from gun hose using P3 pushbutton. (see Section 4-8).

Manual MIG Welding Advanced Settings

To change all values list, unit must be SETUP FULL. To set unit to
SETUP FULL, proceed as follows:

Press P2 to enter SET UP menu.
Select SET FULL on D1 and D2 (see Section 4-6).

Setting Inductance

Press P2 to enter SET UP menu.
Use E1 to select on D1 ind. D2 shows 100.wi
If necessary, use E2 to adjust inductance value (range is 1% to

200%).

. Higher inductance setting produces a softer weld puddle and

less spatter, but arc starts may be more difficult. Lower induc-

L4

tance setting produces a stiffer weld puddle and more spatter,
but arc starts may be easier.

Wire Feed Speed Unit (only in SETUP FULL)

Use E1 to change D1 to Uni.
D2 value is the default setting of mpm (meters per minute). D2 shows

IS.
Use E2 to change D2 to IPM (inches per minute). D2 shows Inc.
L3 is always on in MIG Manual welding.

Setting Pre-Gas (only in SETUP FULL)

Use E1 to change D1 to PrE.
D2 value is default setting of 0.0 s (range is 0.0 s to 10.0 s).
Use E2 to change D2 value.

Setting Post-Gas (only in SETUP FULL)

Use E1 to change D1 to PoS.
D2 value is default setting of 0.1 s (range is 0.0 s to 10.0 s).
Use E2 to change D2 value.

Setting BurnBack (only in SETUP FULL)

Use E1 to change D1 to bur.
D2 value is default setting of Aut (range is 1% to 200%).
Auto is a setting below 1% that provides an automatic burnback time.
Use E2 to change D2 value.

Setting Run-In (only in SETUP FULL)

Use E1 to change D1 to rin.
D2 value is default setting of Aut (range is 1% to 200%).
Auto is a setting below 1% that provides an automatic run-in time.
Use E2 to change D2 value.
Run-In is the speed of the wire feed before arc starting in percent of

the set wire speed. It is used for improving arc starts.

OM-223 839 Page 16

4-11. Selecting Synergic MIG Welding

E1 D1 D2 E2

L7

P1 P2 P3

L1
Set Synergic MIG welding process on the
power source. L7 is ON.

In Synergic MIG mode, the operator may
need to adjust welding data (wire type, wire
diameter, and gas type) and only one weld
parameter. Generally, wire feed speed is
adjusted and the synergic process auto­matically sets appropriate weld voltage.
Synergic welding also sets many secon­dary welding parameters automatically for
improved weld quality.

Trim parameter appears on D1 and D2:
D1 value is default trim setting of 0.0 T

(range is −5.0 T to 5.0 T).
D2 value is default wire feed speed setting

of 5.0 m/min (minimum (MIN), maximum
(MAX), or default (DEF) values are arbi­trary based on set welding data). Use P2
and E2 to change this display to amperes
or to the thickness of the material.

While Setting Parameters:

- L2 ON means that D1 shows Trim value.

- L3 ON means that D2 shows the wire
speed in meter/min or inch/min.

- L4 ON means that D2 shows the set weld­ing current in amperes.

- L5 ON means that D2 shows the thick­ness of material to weld.

While Welding:

- D1 shows the measured welding voltage
in Volts. L1 is ON.

- D2 shows the measured welding current
in amperes. L4 is ON.

Set wire speed, welding current or material
thickness and welding voltage with E2 and
E1.

Select trigger mode using P1 pushbutton
(see Section 4-4).

If necessary, use P2 to adjust the welding
parameters.

Purge air from gun hose using P3 pushbut­ton (see Section 4-8).

L2 L3 L4 L5

Setting Trim

D1 value is default trim setting of 0.0 T
(range is −5.0 T to 5.0 T).

Trim is an arbitrary value related to MIG arc
length. Higher values produce a longer and
hotter arc. Lower values produce a shorter
and cooler arc. Recommended value for
trim is default setting or near 0.0T. L2 is On.

Synergic MIG Welding Advanced Set­tings

To change all values list, unit must be SET­UP FULL. To set unit to SETUP FULL, pro­ceed as follows:

Press P2 to enter SET UP menu.
Select SETUP FULL on D1 and D2 (see

Section 4-6).

Setting Main Welding Regulations

Enter SET UP and select rEG on D1 with
E1.

D2 shows the main parameter and E2
changes it.

When D2 shows SPE (wire speed) the
main regulation is the speed of the welding
wire. L3 is ON.

When D2 shows A (ampere) the main regu­lation is the welding current in Amperes. L4
is ON.

When D2 shows thc (thickness) the main
regulation is the material thickness in mm.
L5 is ON.

. The modification to the main welding

regulation is confirmed when exiting
the Set Up Menu.

. The measured welding current can be

different from the set value. This differ­ence can be greater if there are
changes on the default parameters
and if the welding conditions are not
conventional. Setting amperage must
be considered a reference.

. Material thickness setting is a refer-

ence value only.

Setting Inductance

Press P2 to enter SET UP menu.
Use E1 to select on D1 ind. D2 shows 100.
If necessary, use E2 to adjust inductance

value (range is 1% to 200%).

. Higher inductance setting produces a

softer weld puddle and less spatter, but
arc starts may be more difficult. Lower
inductance setting produces a stiffer
weld puddle and more spatter, but arc
starts may be easier.

Wire Feed Speed Unit (only in SETUP
FULL)

See Section 4-10.

Setting Pre−Gas (only in SETUP FULL)

See Section 4-10.

Setting Post-Gas (only in SETUP FULL)

See Section 4-10.

Setting Burnback (only in SETUP FULL)

See Section 4-10.

Setting Run-In (only in SETUP FULL)

See Section 4-10.

Setting 3 Level Trigger Mode (only in
SETUP FULL)

Use E1 to change D1 to 3L.1
D2 value is the default setting of 130%

(range is 20% to 200%).
Use E2 to change D2 value.
Use E1 to change D1 to 3L.2
D2 value is the default setting of 80%

(range is 20% to 200%).
Use E2 to change D2 value.
Use E1 to change D1 to 3L.r
D2 value is the default setting of 0.5 s

(range is 0.1 s to 0.5 s).
This value is the ramp time in seconds to

reach the following level wire speed.

OM-223 839 Page 17

4-12. Selecting Synergic Pulsed MIG Welding

E1 D1 D2 E2

L7

L8

P1 P2 P3

L1

L2 L3 L4 L5

Set Synergic Pulsed MIG welding process on the
power source. L7 is On.

Synergic Pulsed MIG welding is a high quality
welding process that produces very little spatter.
This process works well on thin metals such as
stainless steel and aluminum. In Synergic
Pulsed MIG mode, the operator may need to ad­just welding data (wire type, wire diameter, and
gas type) and only one weld parameter. General­ly, wire feed speed is adjusted and the synergic
process automatically sets appropriate weld
voltage. Synergic welding also sets many sec­ondary welding parameters automatically for im­proved weld quality.

Trim parameter appears on D1 and D2:
D1 value is default trim setting of 0.0 T (range is

−5.0 T to 5.0 T).
D2 value is default wire feed speed setting of 5.0
m/min (minimum (MIN), maximum (MAX), or de­fault (DEF) values are arbitrary based on set
welding data). Use P2 and E2 to change this dis­play to amperes or to the thickness of the weld.

While Setting Parameters:

- L2 ON means that D1 shows Trim value.

- L3 ON means that D2 shows the wire speed in
meter/min or inch/min.

- L4 ON means that D2 shows the set welding
current in amperes.

- L5 ON means that D2 shows the thickness of
material to weld.

While Welding:

- D1 shows the measured welding voltage in
Volts. L1 is ON.

- D2 shows the measured welding current in am­peres. L4 is ON.
Set wire speed, welding current or material thick­ness and welding voltage with E2 and E1.
Select trigger mode using P1 pushbutton (see
Section 4-4).
If necessary, use P2 to adjust the welding pa­rameters.
Purge air from gun hose using P3 pushbutton
(see Section 4-8).

Setting Trim

See Section 4-11.

Synergic Pulsed MIG Welding Advanced Set­tings

To change all values list, unit must be SETUP
FULL. To set unit to SETUP FULL, proceed as
follows:

Press P2 to enter SET UP menu.
Select SETUP FULL on D1 and D2 (see Section
4-6).

Setting Main Welding Regulation

See Section 4-11.

Setting Inductance in Synergic Pulsed MIG
Welding

Press P2 to enter SET UP menu.
Use E1 to select on D1 ind. D2 shows 100.
If necessary, use E2 to adjust inductance value
(range is 1% to 200%).
This parameter is related to Pulse Width. Higher
values give a hotter welding arc.

. Change these parameters as little as pos-

sible because the factory settings are pre­ferred for most applications.
Big changes can affect the arc stability and
weld performance.
In general, remain in the 70% to 130%
range.

Wire Feed Speed Unit (only in SETUP FULL)

See Section 4-10.

Setting Pre-Gas (only in SETUP FULL)

See Section 4-10.

Setting Post-Gas (only in SETUP FULL)

See Section 4-10.

Setting Burnback (only in SETUP FULL)

See Section 4-10.

Setting Run-In (only in SETUP FULL)

See Section 4-10.

Setting 3 Level Trigger Mode

See Section 4-11.

Setting Synergic Double Pulsed MIG

. Synergic Double Pulsed MIG process is se-

lected at the power source or recalled in the
wire feeder using Synergic Double Pulsed
programs. All Double Pulse parameters are
selected on the wire feeder. All other MIG
parameters are the same as standard
Pulsed MIG process.

Some metals weld better using the Synergic
Pulsed Welding process due to the unique puls­ing of the welding arc. Heat generated in the
workpiece is generally lower and the arc charac­teristics produce a better weld bead appearance
especially on aluminum. The Synergic Double
Pulsed MIG process allows control all parame­ters to produce high quality welds on aluminum.

. Incorrect settings in Synergic Double

Pulsed Welding process can result in a pro­gram with undesirable weld characteristics.
Setup should only be used by operators fa­miliar with various welding processes and
parameters. In some cases, standard Syn­ergic Pulsed MIG welding can produce bet­ter welds.

Press P2 to enter SET UP menu.
Use E1 to change D1 to 2P.F.
Use E2 to change D2 value.

The range of this setting is 0.1 Hz to 5.0 Hz. This
setting allows changing double pulse frequency
in hertz (cycles per second). A recommended
frequency is approximately 1 hertz.

Use E1 to change D1 to 2P.C.
D2 value is default setting of 50%.
Use E2 to change D2 value.

The range of this setting is 25% to 75%. This set­ting allows changing the time that the pulse is at
high output. A lower setting will produce less
heating at the welding puddle.

Use E1 to change D1 to 2P.O. D2 value is default
setting of 20%. Use E2to change D2 value. The
range of this setting is 20% to 80%. This setting
allows changing the difference in high wire feed
speed and low wire feed speed in percent of the
wire feed speed setting. For example, if the main
wire feed speed is set at 5 M and 2P.0 setting in
D2 is 40%, the wire feed speed will change be­tween 4 m/min and 6 m/min. A recommended
setting is 20%.

Use E1 to change D1 to 2P.A. D2 value is the de­fault setting of 0.0. Use E2 to change D2 value.
The range of this setting is −5.0 to 5.0.
This setting allows changing the low end of trim
in double pulse and the main setting for trim will
be the low end. A higher 2P.A setting will produce
a longer and hotter arc and lower setting will pro­duce a shorter and cooler arc.

OM-223 839 Page 18

SECTION 5 − MAINTENANCE & TROUBLESHOOTING

5-1. Routine Maintenance

5-2. Help Displays

Replace

Damaged Or

Unreadable

Labels

Clean

Drive
Rolls

Y Disconnect power

before maintaining.

3 Months

Replace Damaged

Gas Hose

6 Months

. Maintain more often

during severe conditions.

Clean And

Tighten

Weld

Terminals

Repair Or Replace

Cracked Cables

And Cords

Blow Out Or

Vacuum Inside

The XMC 44 microprocessor controls all internal parameters of the
units.

In case of failure, D1 and D2 will show the following Error Signals.

HLP 100

Indicates that the 24 volt AC supplied to the unit is low.
Verify the supply to the unit and the circuit breaker status on both the

wire feeder and on the power source.

HLP 101

Indicates that the current in the motor is too high.
Verify that the wire has not stopped.

HLP 102

Indicates that the voltage on the motor is too high.
Verify that the wire has not stopped.

HLP 103

Indicates that there is a short circuit in the motor or in the cabling.

Verify that the motor and cabling are functioning.

HLP 104

Indicates that the motor speed is too low or the encoder on the motor
is giving incorrect signals.

Verify that the motor has not stopped and check the cabling of the en­coder.

HLP 105

Indicates a communication error between the power source and the
wire feeder.

Verify that all the connectors in the path from the control board of the
power source and the motor board of the wire feeder are correctly
fixed.

HLP 106

Indicate that there is a communication error in the RS 485.
Verify that all the connectors in the path from the control board of the

power source and the motor board of the wire feeder are correctly
fixed.

OM-223 839 Page 19

5-3. Troubleshooting

Problem Solution

Unit is completely inoperative. Check continuity of Power switch S1, and replace if necessary.

Reset circuit breaker CB1 if open.

Check input power source. See welding power source Technical Manual.

Wire does not feed, unit completely inop­erative.

Wire does not feed. Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s

Wire feeds erratically. Readjust hub tension and drive roll pressure.

Electrode wire feeding stops or feeds
erratically during welding.

Wire feeds as soon as power is applied. Check gun trigger. See gun Owner’s Manual.

Gas valve rattles loudly and wire feeds
slowly or erratically.

Turn Power switch On.

Check 14−pin receptacle connections.

Check input power or the CB

Manual.

Have Factory Authorized Service Agent check drive motor and control board PC1.

Use correct size drive roll (see Parts List).

Clean or replace dirty or worn drive roll.

Remove weld spatter around nozzle opening.

Replace contact tip or liner. See gun Owner’s Manual.

Check wiring between Motor Board and Encoder

Realign drive rolls.

Check hub assembly (see Parts List).

Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.

Gas does not flow; wire feeds. Check gas valve and flowmeter.

Wire feeds, but gas does not flow with
gun trigger pressed.

Software or visualization problems.

Wire feeds and electrode wire is ener­gized, but gas flow is irregular.

Motor runs at full speed. Check motor control board and connections, and replace if necessary.

Wire drive motor coasts (no brake at trig­ger release).

Meter does not work properly. Recall factory parameters as explained in this manual.

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.

Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace if necessary.

Clear blockage in gas hose or replace hose.

Clear blockage in gun. See gun Owner’s Manual.

Check wiring between Motor Board and Encoder

Check motor control board PC1 and connections, and replace if necessary.

OM-223 839 Page 20

SECTION 6 − ELECTRICAL DIAGRAM

May 9, 2005

OM-223 839 Page 21

. Hardware is common and

not available unless listed.

SECTION 7 − PARTS LIST

11

10

9

8

7

12

13

14

2

1

33

32

3

4

6

5

31

30

29

2728

26

25

24

23

15

22

21

20

16

17

19

.

18

OM-223 839 Page 22

May 9, 2005

Figure 7-1. Main Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 7-1. Main Assembly

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-223 839 Page 23

. Hardware is common and

not available unless listed.

19

18

4

20

21

22

23

24

25

1

2

3

4

5

May 9, 2005

14

15

17

16

6

7

8

9

10

11

12

13

Figure 7-2. Wire Drive Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 7-2. Wire Drive Assembly

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

Quantity

Table 7-1. Drive Roll And Wire Guide Kits (4 Drive Roll)

Kit N

NOTE

Base selection of drive rolls upon the following recommended usages:

1. V-Grooved rolls for hard wire.

2. U-Grooved rolls for soft and soft shelled cored wires.

3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).

4. V-Knurled rolls for hard shelled cored wires.

5. Drive roll types may be mixed to suit particular requirements (example:
V-Knurled roll in combination with U-Grooved).

Wire Diameter

Metric Fraction Decimal

0.6 mm 0.023/0.025 in 0.023/0.025 in 087 132 087 130 V-Grooved 056 192 056 206

0.8 mm 0.030 in 0.030 in 046 780 053 695 V-Grooved 056 192 056 206

0.9 mm 0.035 in 0.035 in 046 781 053 700 V-Grooved 056 192 056 206

1.0/1.2 mm 0.035/0.045 in 0.035/0.045 in N/A 189 285 V-Grooved 156 193 056 207

1.0 mm 0.040 in 0.040 in 191 917 053 696 V-Grooved 056 192 056 206

1.2 mm 0.045 in 0.045 in 046 782 053 697 V-Grooved 056 193 056 207

1.6 mm 1/16 in 0.062 in 046 784 053 699 V-Grooved 056 195 056 209

0.9 mm 0.035 in 0.035 in 044 750 072 000 U-Grooved 056 192 056 206

1.2 mm 0.045 in 0.045 in 046 785 053 701 U-Grooved 056 193 056 207

1.3 mm 0.052 in 0.052 in 046 786 053 702 U-Grooved 056 193 056 207

1.6 mm 1/16 in 0.062 in 046 787 053 706 U-Grooved 056 195 056 209

2.0 mm 5/64 in 0.079 in 046 788 053 704 U-Grooved 056 195 056 209

0.9 mm 0.035 in 0.035 in 046 782 132 958 V-Knurled 056 192 056 206

1.2 mm 0.045 in 0.045 in 046 793 132 957 V-Knurled 056 193 056 207

1.3 mm 0.052 in 0.052 in 046 794 132 956 V-Knurled 056 193 056 207

1.6 mm 1/16 in 0.062 in 046 795 132 955 V-Knurled 056 195 056 209

1.8 mm 0.068-0.072 in 0.068-0.072 in 089 985 132 959 V-Knurled 056 195 056 209

2.0 mm 5/64 in 0.079 in 046 796 132 960 V-Knurled 056 195 056 209

1.2 mm 0.045 in 0.045 in 083 319 083 489 U-Cogged 056 193 056 207

1.3 mm 0.052 in 0.052 in 083 320 083 490 U-Cogged 056 193 056 207

1.6 mm 1/16 in 0.062 in 046 800 053 708 U-Cogged 056 195 056 209

2.0 mm 5/64 in 0.079 in 046 801 053 710 U-Cogged 056 195 056 209

o.

Part No. Type Inlet Intermediate

Drive Roll Wire Guide

OM-223 839 Page 25

Notes

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.

Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date 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.

1. 5 Years Parts − 3 Years Labor
* Original main power rectifiers
* Inverters (input and output rectifiers only)

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
* 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
* 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
* Plasma Cutting Torches (except APT & SAF

Models)

* 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.)

5 6 Months — Batteries

6. 90 Days — Parts
* MIG Guns/TIG Torches
* Induction heating coils and blankets

* 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:

1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.

2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the
goods at customer’s risk and expense. Miller’s option of
repair or replacement will be F.O.B., Factory at ITW Welding
Products Group Europe, or F.O.B. at a Miller authorized
service facility as determined by Miller. Therefore no
compensation or reimbursement for transportation costs of
any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL Miller BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
AND DISCLAIMED BY MILLER.

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.

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.

milan_warr 1/06

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

Country Zip/Postal Code

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Contact the Delivering Carrier to:

Welding Supplies and Consumables
Options and Accessories
Service and Repair
Replacement Parts
Owner’s Manuals

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.

ITW Welding Products Italy S.r.l.

Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: [phone]
Fax: [phone]
email: miller@itw−welding.it

PRINTED IN USA © 2006 Miller Electric Mfg. Co. 1/06