MILLER XMS 44 (01) PDF Document

To connect a welding gun to your MILLER XMS 44, follow these steps:

1. Loosen the Gun Securing Knob (1).

2. Insert the gun into the Gun Block (2).

3. Position the Gun Outlet Wire Guide (3) as close as possible to the drive rolls without it touching them.

4. Tighten the securing knob.

5. If applicable, connect the Gun Trigger Plug (4) to the Gun Trigger Receptacle (5).

Note: For a US Gun, you may need specific equipment from the manufacturer. For water-cooled guns, make cooling system connections as required.

To install and align the wire guide and drive rolls on your MILLER XMS 44:

1. Install and secure the Inlet Wire Guide (1) and the Intermediate Wire Guide (2).

2. Install the four Drive Rolls (3) and turn each drive roll nut one click.

3. To align the components, view from the top of the drive rolls with the pressure assembly open.

4. Turn the alignment screw in or out until the drive roll groove lines up perfectly with the wire guide.

5. Close the pressure roll assembly.

6. Repeat this alignment process for the remaining drive rolls until all are correctly aligned with the wire guides.

Make the following connections, ensuring they are all tight:

1. Connect the 14 Pin Control Cord.

2. Connect the Weld Cable to the connection inside the wire feeder.

3. Connect the Gas Hose to the feeder using the supplied clamp. Connect the other end of the gas hose to the power source gas cylinder or gas circuit.

4. If using a water cooler, connect the Blue Quick Connect Fitting (Coolant Output to Gun).

5. If using a water cooler, connect the Red Quick Connect Fitting (Coolant Return From Gun).

6. Connect the Work Cable Clamp.

7. Secure the cables with the Cable Bundle Collar.

Before starting, disconnect all power to the units.

1. Remove the screws securing the Access Door (1), Clamp (2), and Plastic Collar (3).

2. Connect the weld cable to the terminals located behind the access door.

3. Reinstall the clamp, collar, and door securely.

1. Remove the existing rubber feet from the bottom of the wire feeder.

2. If the unit will be used on level floors or an optional turntable, you can install only the wheels.

3. For increased stability on uneven floors, install both the wheels and the bars.

4. Secure the wheels (1) and bars (2) using the provided screws (3).

The control panel of the MILLER XMS 44 includes the following components:

Connectors and Receptacles:

• 1. MIG Gun Connector: For connecting the MIG gun.

• 2. Red Quick Connect Fitting: Coolant return from the gun.

• 3. Blue Quick Connect Fitting: Coolant output to the torch.

• 4. Remote Control Receptacle: For connecting an optional remote control.

Displays and Controls:

• 7. D1 (Display 1): Shows values and parameters for the selected welding process.

• 8. D2 (Display 2): Shows values and parameters for the selected welding process.

• 9. E1 (Encoder Control 1): Changes values and parameters shown on Display D1.

• 10. E2 (Encoder Control 2): Changes values and parameters shown on Display D2.

Push Buttons:

• 11. P1 (Trigger Selection): Selects the desired trigger mode.

• 12. P2 (Memory/Setup): Selects Memory and Setup menus for MIG welding.

• 13. P3 (Jog/Purge): Performs jog and purge operations.

Indicator LEDs:

• L1 ON: D1 shows voltage.

• L2 ON: D1 shows Trim value.

• L3 ON: D2 shows Wire Speed.

• L4 ON: D2 shows Amperage.

• L5 ON: D2 shows Material Thickness.

• L6: Manual MIG welding is selected.

• L7: Synergic MIG welding is selected.

• L8: Synergic Pulsed MIG welding is selected.

• L9: Synergic Double Pulsed MIG welding is selected.

• L10 ON: 2 times trigger function is selected.

• L11 ON: 4 times trigger function is selected.

• L12 ON: 3 levels trigger function is selected.

• L13 ON: Setup menu is selected.

• L14 ON: Memory menu is selected.

• L15 ON: Jog function is selected.

• L16 ON: Purge function is selected.

Switching On:

Install the power source and wire feeder according to their manuals and turn on the welding power source. Displays D1 and D2 will show the software version, then the unit will be ready to weld with either factory default values or the values from the last weld.

Recalling Factory Parameters:

It is recommended to write down any custom parameters before performing this procedure, as they will be erased.

1. Turn the power source Off, then turn it On again.

2. Immediately press and hold the wire feeder buttons P1 and P3 simultaneously.

3. Release P1 and P3 when “MEM CLR” appears on displays D1 and D2.

4. When “DON” appears on D1, turn the power source Off.

5. All parameters will return to factory default settings the next time the unit is turned on.

MIG welding process selection is made on the power source. The MILLER XMS 44 wire feeder indicates the selected process with four LEDs (L6, L7, L8, L9). The displays will show either factory default settings or the last settings entered for that process.

• L6 – Manual MIG welding:

D1 displays welding voltage (default 18.5V).

D2 displays wire feed speed (default 5 m/min).

• L7 – Synergic MIG welding (non-pulsed):

D1 displays Trim (default 0.0 T).

D2 displays wire feed speed.

• L8 – Synergic Pulsed MIG welding:

D1 displays Trim (default 0.0).

D2 displays wire feed speed.

• L9 – Synergic Double Pulsed MIG welding:

D1 displays Trim (default 0.0).

D2 displays wire feed speed.

Always check and set a trigger mode for your welding process. Press the P1 button to select the desired trigger mode, indicated by LEDs L10, L11, and L12.

• L10 ON – 2 Times Trigger Function:

Press trigger to start welding.

Release trigger to stop welding.

• L11 ON – 4 Times Trigger Function:

Press trigger to start welding.

Release trigger and welding continues.

Press and release trigger a second time to stop welding.

• L12 ON – 3 Levels Trigger Function (useful for aluminum/crater fill):

Press trigger to start welding with level 1 parameters.

Release trigger and welding continues with main parameters.

Press trigger a second time and welding continues at level 2 parameters.

Release trigger a second time to stop welding.

Availability of trigger modes depends on the selected welding process.

You cannot weld while in the Setup or Memory menus. To access these menus, use the P2 button.

1. Press P2 once to select the Setup Menu (L13 is ON).

2. Press P2 a second time to select the Memory Menu (L14 is ON).

3. Press P2 again to exit both menus (L13 and L14 are OFF).

Setup Menu (L13 ON):

This menu allows you to view and change default parameter values for all welding processes. D1 shows the parameter, D2 shows its value. E1 changes the parameter, and E2 changes the value. Press P2 to exit and save changes. You can also select the menu type: “SHO” (short) for basic parameters or “FULL” for all parameters.

Memory Menu (L14 ON):

This menu allows you to save and recall up to 99 sets of personal welding parameters (P.01 to P.99).

• Use E1 to select a memory position (e.g., P.01).

• Use E2 to select an action for that position: “Ld” (load), “Sto” (store/save), or “dEL” (delete).

• To confirm the action, press and hold P2 until the displays flash, then release and wait for flashing to stop. The welder will then exit the Memory menu.

The P3 button controls both Jog and Purge functions.

To use the Jog function (feeds wire without welding):

1. Press P3 once. The Jog LED (L15) will illuminate.

2. Press and hold P3 to perform the jog function. Display D1 will show “JOG” and D2 will show the wire feed speed.

3. Use Encoder E2 to change the jog speed if needed.

To use the Purge function (flows shielding gas without welding):

1. From the jog selection, press P3 a second time. The Purge LED (L16) will illuminate.

2. Press and hold P3 to perform the purge function.

If a function is selected but not used within several seconds, the corresponding LED will turn off.

1. Following all safety precautions, prepare the unit according to the installation instructions.

2. Using a proper adapter, connect the gun to the MIG gun connector (1).

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

4. If using a water-cooled gun, connect the input coolant hose to the blue quick connect fitting (2) and the return coolant hose to the red quick connect fitting (3). Check coolant levels.

5. If a remote control is desired, connect it to the Remote Control receptacle (4).

6. Turn the unit On and allow its start-up cycle to complete.

7. Set the MIG welding process on the Power Source and verify the indicator lights on the wire feeder.

8. Purge air from the gas hose using the P3 pushbutton.

During Setting:

1. Set the Manual MIG welding process on the power source. LED L6 will be On.

2. Display D1 shows the voltage setting (default 18.5 V). Use encoder E1 to change voltage.

3. Display D2 shows the wire feed speed setting (default 5.0 m/min). Use encoder E2 to change wire feed speed.

While Welding:

• D1 shows the measured welding voltage in volts (L1 is On).

• D2 shows the measured welding current in amperes (L4 is On).

Advanced Settings (Requires SETUP FULL mode):

To access all advanced settings, enter the Setup Menu (press P2), select “SET” on D1 with E1, and change D2 to “FULL” with E2.

• Inductance (ind): Adjusts the arc characteristics. Range is 1% to 200%. Higher settings produce a softer puddle with less spatter but may make arc starts more difficult. Lower settings produce a stiffer puddle with more spatter but easier arc starts.

• Wire Feed Speed Unit (Uni): Change between mpm (meters per minute) and IPM (inches per minute).

• Pre-Gas (PrE): Sets the time gas flows before the arc starts. Range is 0.0 s to 10.0 s.

• Post-Gas (PoS): Sets the time gas flows after the arc stops. Range is 0.0 s to 10.0 s.

• Burnback (bur): Prevents the wire from sticking in the puddle. Range is 1% to 200%, with an “Aut” setting for automatic burnback time.

• Run-In (rin): Sets the wire speed before arc starting as a percentage of the set wire speed to improve arc starts. Range is 1% to 200%, with an “Aut” setting.

In Synergic MIG mode, the process automatically sets the appropriate weld voltage when you adjust the wire feed speed. The display also shows a Trim parameter.

1. Set the Synergic MIG process on the power source. LED L7 will be On.

2. Display D1 shows the Trim parameter (default 0.0 T). Trim is an arbitrary value related to MIG arc length. Higher values produce a longer, hotter arc; lower values produce a shorter, cooler arc. Use E1 to adjust Trim.

3. Display D2 shows the primary parameter: wire feed speed, amperage, or material thickness. Use E2 to adjust this parameter. You can change which parameter is displayed and adjusted using the advanced settings.

While Welding:

• D1 shows the measured welding voltage in Volts (L1 is On).

• D2 shows the measured welding current in amperes (L4 is On).

Advanced Settings (Requires SETUP FULL mode):

• Main Welding Regulation (rEG): Choose what E2 adjusts: SPE (wire speed), A (amperage), or thc (material thickness).

• Inductance (ind): Adjusts arc characteristics from 1% to 200%.

• 3 Level Trigger Mode: Set percentages for the start (3L.1) and end (3L.2) levels, and the ramp time (3L.r) between levels.

Other advanced settings like Pre-Gas, Post-Gas, Burnback, and Run-In are also available, similar to Manual MIG mode.

These processes provide high-quality welds with very little spatter, especially on thin metals. Operation is similar to standard Synergic MIG, but with additional parameters available in the advanced settings menu.

Standard Synergic Pulsed MIG (L8 ON):

1. Set the Synergic Pulsed MIG process on the power source.

2. Adjust Trim on D1 using E1.

3. Adjust the main parameter (wire speed, amps, or thickness) on D2 using E2.

Advanced Settings for Synergic Double Pulsed MIG (Requires SETUP FULL mode):

This process is selected at the power source or recalled from memory. It is especially useful for aluminum. All parameters are set on the wire feeder.

• Double Pulse Frequency (2P.F): Sets cycles per second (0.1 Hz to 5.0 Hz). Recommended is approx. 1 Hz.

• Double Pulse Cycle (2P.C): Sets the percentage of time the pulse is at high output (25% to 75%). Lower settings reduce heat input.

• Double Pulse Offset (2P.O): Sets the difference between high and low wire feed speed as a percentage of the main speed setting (20% to 80%). A recommended setting is 20%.

• Double Pulse Trim (2P.A): Sets the low end of trim in the double pulse (-5.0 to 5.0). A higher setting gives a longer, hotter arc; a lower setting gives a shorter, cooler arc.

Before performing maintenance, disconnect all power. Perform maintenance more often during severe conditions.

Every 3 Months:

• Replace any damaged or unreadable labels.

• Replace the damaged gas hose.

• Clean and tighten weld terminals.

Every 6 Months:

• Clean the drive rolls.

• Repair or replace any cracked cables and cords.

• Blow out or vacuum dust and dirt from inside the unit.

If a failure occurs, displays D1 and D2 will show an error signal. Here is a list of codes and their meanings:

• HLP 100: The 24 volt AC supply to the unit is low. Verify the supply and the circuit breaker status on both the wire feeder and the power source.

• HLP 101: The current in the motor is too high. Verify that the wire has not stopped.

• HLP 102: The voltage on the motor is too high. Verify that the wire has not stopped.

• HLP 103: There is a short circuit in the motor or in the cabling. Verify that the motor and cabling are functioning.

• HLP 104: 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: Communication error between the power source and the wire feeder. Verify that all connectors between the control board of the power source and the motor board of the wire feeder are correctly fixed.

• HLP 106: Communication error in the RS 485. Verify that all connectors between the control board of the power source and the motor board of the wire feeder are correctly fixed.

Base your selection of drive rolls on the following recommended uses:

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 (e.g., hard surfacing types).

4. V-Knurled rolls: For hard shelled cored wires.

The table below lists the appropriate kits for various wire diameters.