Related Manuals for Miller Electric XMS 44
Summary of Contents for Miller Electric XMS 44
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Page 1: Wire Feeder
XMS 44 Wire Feeder OWNER’S MANUAL OM-223 839B 2006−07 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder... - Page 2 Warranty and service information for your particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2. - Page 4 Via dell’Industria, 55 36030 Sarcedo Vincenza, Italy Phone: 39(0445)367706 European Contact Signature: XMS 44 Declares that this product: conforms to the following Directives and Standards: 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 Electromagnetic Compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995...
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Page 5: Section 1 − Safety Precautions - Read Before Using
DC 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! D Disconnect input power or stop engine before installing or servicing this equipment. - Page 6 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.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
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. -
Page 8: Principal Safety Standards
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard F4.1 from Global... -
Page 9: Section 2 − Definitions
SECTION 2 − DEFINITIONS 2-1. Manufacturer’s Warning Label Definitions 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. -
Page 10: Manufacturer's Rating Labels
2-2. Manufacturer’s Rating Labels 2-3. Symbols And Definitions NOTE Symbols found on product. Amperes Degree Of Protection Read Instructions Purge Conventional Load Voltage Symbols not shown here are detailed in this manual when they are relevant. OM-223 839 Page 6 Volts Hertz Primary Voltage... -
Page 11: Section 3 − Introduction
Serial communication signal +485. Start motor signal to XMS 44. Trigger switch signal to XMS 4000. Circuit common for 24 volts AC circuit. Wire feeder speed signal to XMS 44. *The remaining pins are not used. Wire Feed Wire Diameter Range Speed Range 0.8 mm −... -
Page 12: Connecting Welding Gun
3-4. Connecting Welding Gun 3-5. Installing Wire Guide And Drive Roll Tools Needed: 3/8 in OM-223 839 Page 8 US Gun Euro Gun 1−2 Correct Alignment Incorrect Alignment 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. -
Page 13: Circuit Protection
3-6. Circuit Protection 3-7. Connecting Wire Feeder to Power Source 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. Make connections as shown. Be sure connections are tight. -
Page 14: Changing Cable Between Wire Feeder And Xms 4000
3-8. Changing Cable Between Wire Feeder and XMS 4000 Tools Needed: 3-9. Installing Wheels On Wire Feeder (Optional) Tools Needed: OM-223 839 Page 10 Y Disconnect power before Connect weld cable to terminals be- hind access door. Remove screws securing door, clamp and collar. -
Page 15: Section 4 − Operation
SECTION 4 − OPERATION 4-1. Control Panel 16 17 18 MIG Gun Connector Red Quick Connect Fitting (Coolant Return From Gun). Blue Quick Connect Fitting (Coolant Output To Torch) Remote Control Receptacle Handle Panel D1 − (Display 1) Displays values and parameters for selected welding process. -
Page 16: Switching On Unit And Recalling Factory Parameters
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. 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. -
Page 17: Trigger Mode Selection
4-4. Trigger Mode Selection Always check and set a trigger mode. If trigger mode is undefined for a weld- ing 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. -
Page 18: Setup Menu
E2 changes the action on the memory posi- tion. 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. -
Page 19: Preparing Unit For Mig Welding
4-9. Preparing Unit For MIG Welding To select MIG welding process, pro- ceed as follows: Follow safety precautions according to Section 1. Prepare unit according to Section 3. Using a cable with a proper adapter, connect gun to the MIG gun connector. -
Page 20: Selecting Manual Mig Welding
4-10. Selecting Manual MIG Welding 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). -
Page 21: Selecting Synergic Mig Welding
4-11. Selecting Synergic MIG Welding 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. -
Page 22: Selecting Synergic Pulsed Mig Welding
4-12. Selecting Synergic Pulsed MIG Welding 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. -
Page 23: Section 5 − Maintenance & Troubleshooting
SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Replace Damaged Or Unreadable Labels 5-2. Help Displays The XMC 44 microprocessor controls all internal parameters of the units. In case of failure, D1 and D2 will show the following Error Signals. HLP 100 Indicates that the 24 volt AC supplied to the unit is low. -
Page 24: Troubleshooting
5-3. Troubleshooting Problem 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. Turn Power switch On. Wire does not feed, unit completely inop- erative erative. -
Page 25: Section 6 − Electrical Diagram
SECTION 6 − ELECTRICAL DIAGRAM May 9, 2005 OM-223 839 Page 21... -
Page 26: Section 7 − Parts List
SECTION 7 − PARTS LIST Hardware is common and not available unless listed. OM-223 839 Page 22 Figure 7-1. Main Assembly May 9, 2005... - Page 27 Item Dia. Part Mkgs..... . V57052030 ..... . 028066243 .
- Page 28 Hardware is common and not available unless listed. Item Dia. Part Mkgs. Figure 7-2. Wire Drive Assembly ....057010052 ..
- Page 29 Table 7-1. Drive Roll And Wire Guide Kits (4 Drive Roll) 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.
- Page 30 Notes...
- Page 31 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.
- Page 32 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. 2006 Miller Electric Mfg. Co. 1/06 TW Welding Products Italy S.r.l. Via Privata Iseo, 6/E 20098 San Giuliano Milanese, Italy...