Instruction/ maintenance manual of the product XMS 44 Miller Electric
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Processes Description MIG (GMAW) W elding Flux Cored (FCA W ) W elding Wire Feeder OM-223 839B 2006 − 07 XMS 44 W ire Feeder OWNER’S MANUAL.
Thank you and congratulations on choosing Miller . Now you can get the job done and get it done right. W e 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 .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
dec_stat_Milan_6/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit).
OM-223 839 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown i n the adjoining symbols.
OM-223 839 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
OM-223 839 Page 3 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.
OM-223 839 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .
OM-223 839 Page 5 SECTION 2 − DEFINITIONS 2-1. Manufacturer ’ s W arning Label Definitions 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 56 + 2.3 S-178 936 1. W arning! W atch Out! There are possible hazards as shown by the symbols. 2. Drive rolls can injure fingers 3.
OM-223 839 Page 6 1 W arning! W atch 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 . 1 2 3 2-2. Manufacturer ’ s Rating Labels 2-3.
OM-223 839 Page 7 SECTION 3 − INTRODUCTION 3-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating Overall Dimensions W eight 24 V olts AC Single-Phase 7 Amperes 50/60 Hertz XMS 4000 Welding Power Source 0.
OM-223 839 Page 8 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 touching. T ighten knob. 4 Gun Trigger Plug 5 Gun Trigger Receptacle .
OM-223 839 Page 9 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.
OM-223 839 Page 10 3-8. Changing Cable Between Wire Feeder and XMS 4000 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 .
OM-223 839 Page 1 1 SECTION 4 − OPERA TION 4-1. Control Panel 1 MIG Gun Connector 2 Red Quick Connect Fitting (Coolant Return From Gun). 3 Blue Quick Connect Fitting (Coolant Output T o T orch) 4 Remote Control Receptacle 5 Handle 6 Panel 7 D1 − (Display 1) Displays values and parameters for selected welding process.
OM-223 839 Page 12 4-2. Switching On Unit And Recalling Factory Parameters Install power source and wire feeder ac- cording to supplied Owner ’s Manuals.
OM-223 839 Page 13 4-4. T rigger Mode Selection . Always check and set a trigger mode. If trigger mode is undefined for a weld- ing process, select the desired mode. T rigger 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.
OM-223 839 Page 14 4-6. Setup Menu Press P2 t o 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.
OM-223 839 Page 15 4-9. Preparing Unit For MIG Welding T o select MIG welding process, pro- ceed 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 .
OM-223 839 Page 16 4-10. Selecting Manual MIG W elding 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.
OM-223 839 Page 17 4-1 1. Selecting Synergic MIG W elding 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 .
OM-223 839 Page 18 4-12. Selecting Synergic Pulsed MIG W elding Se t 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.
OM-223 839 Page 19 SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions.
OM-223 839 Page 20 5-3. T roubleshooting 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 T echnical Manual.
OM-223 839 Page 21 SECTION 6 − ELECTRICAL DIAGRAM May 9, 2005.
OM-223 839 Page 22 SECTION 7 − P ARTS LIST . Hardware is common and not available unless listed. May 9, 2005 . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Figure 7-1.
OM-223 839 Page 23 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly Quantity 1 V57052030 Euro adapter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-223 839 Page 24 . Hardware is common and not available unless listed. May 9, 2005 1 2 3 4 5 6 7 8 9 10 11 12 13 4 14 15 16 17 18 19 20 21 22 23 24 25 Figure 7-2. Wire Drive Assembly Description Part No. Dia. Mkgs. Item No. Figure 7-2. Wire Drive Assembly Quantity 1 M 057010052 Motor , 24 VDC, 60 W 1 .
OM-223 839 Page 25 T able 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).
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 W ARRANTY − Subject to the terms and conditions below , ITW W elding Products Italy S.
PRINTED IN USA © 2006 Miller Electric Mfg. Co. 1/06 I TW W elding 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 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.
An important point after buying a device Miller Electric XMS 44 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric XMS 44 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric XMS 44 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric XMS 44 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric XMS 44 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric XMS 44, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric XMS 44.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric XMS 44. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric XMS 44 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
