Miller XMS 44 User manual

Processes
Description
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Wire Feeder
OM-223 839H 2014−03
XMS 44
Wire Feeder
OWNER’S MANUAL
CE
Visit our website at
www.MillerWelds.com

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.
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 catalog sheets.
Working as hard as you do
− every power source from
Miller is backed by the most
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From Miller to You

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 4.......................................................
1-5. Principal Safety Standards 4.............................................................
1-6. EMF Information 4......................................................................
SECTION 2 − DEFINITIONS 5...................................................................
2-1. Additional Safety Symbols And Definitions 5................................................
2-2. Miscellaneous Symbols And Definitions 6...................................................
SECTION 3 − INTRODUCTION 7.................................................................
3-1. Important Information Regarding CE Products (Sold Within The EU) 7...........................
3-2. Serial Number And Rating Label Location 7.................................................
3-3. Specifications 7........................................................................
3-4. Environmental Specifications 7...........................................................
3-5. Remote 7 Receptacle Information 8........................................................
3-6. 14-Pin Plug Information 8................................................................
3-7. Connecting Welding Gun 9...............................................................
3-8. Installing Wire Guide And Drive Roll 10......................................................
3-9. Circuit Protection 11.....................................................................
3-10. Connecting Wire Feeder to Power Source 11.................................................
3-11. Changing Cable Between Wire Feeder and XMS 403 12.......................................
3-12. Installing Wheels On Wire Feeder (Optional) 12...............................................
SECTION 4 − OPERATION 13....................................................................
4-1. Control Panel 13.........................................................................
4-2. Switching On Unit And Recalling Factory Parameters 14.......................................
4-3. Welding Process Selection 14.............................................................
4-4. Trigger Mode Selection 15................................................................
4-5. Setup Menu and Memory Menu Selection 15.................................................
4-6. Setup Menu 16..........................................................................
4-7. Memory Menu 16........................................................................
4-8. Jog And Purge Selection 16...............................................................
4-9. Preparing Unit For MIG Welding 17.........................................................
4-10. Selecting Manual MIG Welding 18..........................................................
4-11. Selecting Synergic MIG Welding 19.........................................................
4-12. Selecting Synergic Pulsed MIG Welding 20..................................................
SECTION 5 − MAINTENANCE & TROUBLESHOOTING 21...........................................
5-1. Routine Maintenance 21..................................................................
5-2. Help Displays 21........................................................................
5-3. Troubleshooting 22......................................................................
SECTION 6 − ELECTRICAL DIAGRAM 23..........................................................
SECTION 7 − PARTS LIST 24.....................................................................
WARRANTY

DECLARATION OF CONFORMITY
for European Community (CE marked) products.
ITW Welding Products Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that
the product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product Stock Number
XMS 44 029007424
Council Directives:
•2006/95/EC Low Voltage
•2004/108/EC Electromagnetic Compatibility
•2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
•IEC 60974-1 Arc Welding Equipment - Welding Power Sources: edition 3, 2005-07.
•IEC 60974-5 Arc Welding Equipment – Wire Feeders: edition 2, 2007-11.
•IEC 60974-10 Arc Welding Equipment - Electromagnetic Compatibility Requirements: edition 2.0, 2007-08.
•EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding, arc
welding and allied processes with the basic restrictions related to human exposure to electromagnetic fields
(0Hz-300Hz)
EU Signatory:
January 2nd , 2013
___________________________________________________________________________________
Massimigliano Lavarini Date of Declaration
ELECTRONIC ENGINEER R&D TECH.SUPPORT
956 172 038

OM- 223 839 Page 1
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2013−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plainedin the text.
NOTICE − Indicates statements not related to personal injury.
.Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
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.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
Touchinglive electrical parts can cause fatal shock
s
or severe burns. The electrode and work circuit i
s
electricallylive whenever the output is on. The inpu
t
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automati
c
wire welding, the wire, wire reel, drive roll housing
,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperl
y
groundedequipment is a hazard.
DDo not touch live electrical parts.
ELECTRIC SHOCK can kill.
DWear dry, hole-free insulating gloves and body protection.
DInsulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
DDo not use AC output in damp areas, if movement is confined, or if
thereis a danger of falling.
DUse AC output ONLY if required for the welding process.
DIf AC output is required, use remote output control if present on
unit.
DAdditionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locationsor while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
ableor accidental contact with the workpiece or ground. For these
conditions,use the following equipment in order presented: 1) a
semiautomaticDC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age.In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
DDisconnect 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).
DProperly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
DAlways verify the supply ground − check and be sure that input
powercord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
DWhenmaking input connections, attach proper grounding conduc-
tor first − double-check connections.
DKeepcords dry, free of oil and grease, and protected from hot metal
and sparks.
DFrequently inspect input power cord and ground conductor for
damageor bare wiring – replace immediately if damaged – bare
wiring can kill.
DTurn off all equipment when not in use.
DDo not use worn, damaged, undersized, or repaired cables.
DDo not drape cables over your body.
DIf earth grounding of the workpiece is required, ground it directly
with a separate cable.
DDo not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
DDo not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
DUse only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
DWear a safety harness if working above floor level.
DKeep all panels and covers securely in place.
DClamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
DInsulate work clamp when not connected to workpiece to prevent
contact with any metal object.
DDo not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
DUse GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing power sources AFTER removal of input power.
DTurn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
beforetouching any parts.
HOT PARTS can burn.
DDo not touch hot parts bare handed.
DAllow cooling period before working on equip-
ment.
DTo handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothingto prevent burns.

OM- 223 839 Page 2
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
DKeep your head out of the fumes. Do not breathe the fumes.
DIf inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
DIf ventilation is poor, wear an approved air-supplied respirator.
DRead and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables,coolants, degreasers, fluxes, and metals.
DWork in a confined space only if it is well ventilated, or while
wearingan air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lowerthe oxygen level causing injury or death. Be sure the breath-
ing air is safe.
DDo 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.
DDo not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area,the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
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.
DWear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
DWear approved safety glasses with side shields under your
helmet.
DUse protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
DWear body protection made from durable, flame−resistant mate-
rial (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
ARC RAYS can burn eyes and skin.
Welding on closed containers, such as tanks,
drums,or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece,and hot equipment can cause fires and
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.
WELDING can cause fire or explosion.
DRemove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
DDo not weld where flying sparks can strike flammable material.
DProtect yourself and others from flying sparks and hot metal.
DBe alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
DWatch for fire, and keep a fire extinguisher nearby.
DBe aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
DDo not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
DDo not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
DConnect 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.
DDo not use welder to thaw frozen pipes.
DRemove stick electrode from holder or cut off welding wire at
contact tip when not in use.
DWear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothingsuch as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
DRemove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
DAftercompletion of work, inspect area to ensure it is free of sparks,
glowingembers, and flames.
DUse only correct fuses or circuit breakers. Do not oversize or by-
pass them.
DFollowrequirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
DRead and understand the Safety Data Sheets (SDSs) and the
manufacturer s instructions for adhesives, coatings, cleaners,
consumables,coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
DWelding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
DWear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
DShutoff compressed gas supply when not in use.
DAlways ventilate confined spaces or use
approvedair-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EM
F)
can affect Implanted Medical Devices.
DWearers of Pacemakers and other Implante
d
MedicalDevices should keep away.
DImplantedMedical Device wearers should consult their docto
r
and the device manufacturer before going near arc welding, spo
t
welding,gouging, plasma arc cutting, or induction heating
operations.
Noise from some processes or equipment can
damagehearing.
DWear approved ear protection if noise lev-
el is high.
NOISE can damage hearing.
Compressedgas 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.
CYLINDERS can explode if damaged.
DProtect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
DInstall cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
DKeepcylinders away from any welding or other electrical circuits.
DNever drape a welding torch over a gas cylinder.
DNever allow a welding electrode to touch any cylinder.
DNever weld on a pressurized cylinder − explosion will result.
DUse only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
DTurn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
DKeepprotective cap in place over valve except when cylinder is in
use or connected for use.
DUse the right equipment, correct procedures, and sufficientnum-
ber of persons to lift and move cylinders.
DRead and follow instructions on compressed gas cylinders,
associatedequipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

OM- 223 839 Page 3
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
DDo not install or place unit on, over, or near
combustiblesurfaces.
DDo not install unit near flammables.
DDo not overload building wiring − be sure power supply system is
properlysized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
DUse lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
DUse equipment of adequate capacity to lift and
supportunit.
DIf using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
DKeepequipment (cables and cords) away from moving vehicles
when working from an aerial location.
DFollowthe guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
DAllow cooling period; follow rated duty cycle.
DReduce current or reduce duty cycle before
startingto weld again.
DDo not block or filter airflow to unit.
FLYING SPARKS can injure.
DWear a face shield to protect eyes and face.
DShape tungsten electrode only on grinder with
properguards in a safe location wearing proper
face, hand, and body protection.
DSparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
DPut on grounded wrist strap BEFORE handling
boards or parts.
DUse proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can injure.
DKeep away from moving parts.
DKeep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
DDo not press gun trigger until instructed to do
so.
DDo not point gun toward any part of the body,
other people, or any metal when threading
weldingwire.
BATTERY EXPLOSION can injure.
DDo not use welder to charge batteries or jum
p
start vehicles unless it has a battery chargin
g
feature designed for this purpose.
MOVING PARTS can injure.
DKeep away from moving parts such as fans.
DKeep all doors, panels, covers, and guards
closed and securely in place.
DHave only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
DReinstalldoors, panels, covers, or guards when maintenance is
finishedand before reconnecting input power.
READ INSTRUCTIONS.
DRead and follow all labels and the Owner’s
Manualcarefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
DUse only genuine replacement parts from the manufacturer.
DPerform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
H.F. RADIATION can cause interference.
DHigh-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
DHave only qualified persons familiar with
electronicequipment perform this installation.
DThe user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
DIf notified by the FCC about interference, stop using the
equipmentat once.
DHave the installation regularly checked and maintained.
DKeephigh-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimizethe possibility of interference.
ARC WELDING can cause interference.
DElectromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
DBe sure all equipment in the welding area is
electromagneticallycompatible.
DTo reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
DLocate welding operation 100 meters from any sensitive elec-
tronic equipment.
DBe sure this welding machine is installed and grounded
accordingto this manual.
DIf 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.

OM- 223 839 Page 4
1-4. California Proposition 65 Warnings
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.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductiveharm. Wash hands after use.
1-5. Principal Safety Standards
SafetyinWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.orgor purchased from Global Engineering Documents
(phone:[phone], website: www.global.ihs.com).
SafePractices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: [phone], website:
www.global.ihs.com).
SafePractices for Weldingand Cutting Containers that have Held Com-
bustibles,American Welding Society Standard AWS A6.0, from Global
EngineeringDocuments (phone: [phone],
website: www.global.ihs.com).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.organd www. sparky.org).
SafeHandling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga-
net.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
SafePractice For Occupational And Educational Eye And Face Protec-
tion,ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: [phone], web-
site: www.ansi.org).
Standardfor Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: [phone], website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
ApplicationsManual for the Revised NIOSH Lifting Equation, The Na-
tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and
inductionheating operations) creates an EMF field around the welding
circuit. EMF fields may interfere with some medical implants, e.g. pace-
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding,gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.

OM-223 839 Page 5
SECTION 2 − DEFINITIONS
2-1. Additional Safety Symbols And Definitions
.Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not discard product (where applicable) 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.
Safe37 2012−05
Safe57 2012−05
Wear dry insulating gloves. Do not touch electrode (wire) with bare hand. Do not wear wet or damaged gloves.
Protect yourself from electric shock by insulating yourself from work and ground.
Safe58 2012−06
Disconnectinput plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe59 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe60 2012−06
Use ventilating fan to remove fumes.
Safe61 2012−06
Keepflammables away from welding. Do not weld near flammables.
Safe62 2012−06
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe63 2012−06

OM-223 839 Page 6
?Do not weld on drums or any closed containers.
Safe64 2012−06
Do not remove or paint over (cover) the label.
Safe20 2012−05
Drive rolls can injure fingers.
Safe32 2012−05
Weldingwire and drive parts are at welding voltage during operation − keep hands and metal objects away.
Safe33 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe66 2012−06
Becometrained and read the instructions before working on the
machine or welding.
Safe65 2012−06
2-2. Miscellaneous Symbols And Definitions
.Some symbols are found only on CE products.
On Off Input Output
AAmperes VVolts Alternating Current XDuty Cycle
IP
Degree Of
Protection Hz Hertz Circuit Breaker Wire Feed
Read Instructions
U
1Primary Voltage Gas Metal Arc
Welding (GMAW) Line Connection
Purge Remote Water (Coolant)
Input Water (Coolant) Output
U
2Conventional
Load Voltage
I
1Primary Current
I
2Rated Welding
Current

OM-223 839 Page 7
SECTION 3 − INTRODUCTION
3-1. Important Information Regarding CE Products (Sold Within The EU)
!This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
SThe EMF assessment on this equipment was conducted at 0.5 meter.
SAt a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
!This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltagesupply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con-
ducted as well as radiated disturbances. ce-emc 3 2011-09
3-2. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back . Use rating label to determine input power requirements and/or rated
output.For future reference, write serial number in space provided on back cover of this manual.
3-3. Specifications
Type of Input
Power Welding Power Source Type Wire Feed Speed Range Wire Diameter Range Welding Circuit Rating Overall Dimensions Weight
24 Volts AC
Single-Phase
7 Amperes
50/60 Hertz
XMS 403 Welding
Power Source 0.5 − 20 m/min 0.8 mm − 1.8 mm
Max Spool Weight:
15 kg
36 Volts,
400 Amperes,
30% Duty Cycle
Length: 640 mm
Width: 230 mm
Height: 435 mm 18 kg
3-4. Environmental Specifications
IP Rating Operating Temperature Range Storage Temperature Range
IP23S
This equipment is designed for outdoor use. It
may be stored, but is not intended to be used
outside during precipitation unless sheltered.
−10 to 40°C (14 to 104 °F) 20 to 25°C (68 to 77 °F)

OM-223 839 Page 8
3-5. Remote 7 Receptacle Information
Remote7
Ref. 956142646-3-A
Pin Pin Information
1+10 volts DC supply voltage to remote control
2GND Remote control circuit common
3IREF 0 to 10 current control signal
4VREF 0 to 10 voltage control signal
5UP 0V/10V digital signal
6DOWN 0V/10V digital signal
7TYPE 0V/10V digital signal
.This remote receptacle cannot be used with a standard Miller remote control. A customer supplied remote control is required to use the remote
receptacle.
3-6. 14-Pin Plug Information
Pin* Pin Information
A24 volts AC with respect to socket G. Protected by circuit breaker CB1.
BGND of communication signals.
CSerial communication signal −485.
DSerial communication signal +485.
EStart motor signal to XMS 44.
FTrigger switch signal to XMS 403.
GCircuit common for 24 volts AC circuit.
HWire feeder speed signal to XMS 44.
*The remaining pins are not used.
Use the proper interconnecting cables (P/N 058 019 140−141−142) to connect the unit to the XMS 403.

OM-223 839 Page 9
3-7. Connecting Welding Gun
956142646-6-B
4
US Torch
5
3
2
1
Euro Torch
2
1
1 Gun Securing Screw
2 Gun Block
3 Gun Outlet Wire Guide
Loosenknob, insert gun into block.
Positionoutlet wire guide as close
as possible to drive rolls without
touching.Tighten knob.
4 Gun Trigger Plug
5 Gun Trigger Receptacle
.Contact manufacturer for
equipmentneeded to connect
US Gun.
.Make cooling system connec-
tions as shown in Section 3-10.

OM-223 839 Page 10
1 InletWire 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
lookingdown with pressure assem-
bly open.
Turn screw in or out until drive roll
groove lines up with wire guide.
Close pressure roll assembly.
Repeatfor remaining drive rolls un-
til all drive rolls line up with wire
guidesas shown.
3-8. Installing Wire Guide And Drive Roll
956142675-B
Tools Needed:
3/8 in.
1
2
3
Incorrect Alignment
CorrectAlignment
1−2
3
1/4 in.

OM-223 839 Page 11
3-9. 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
956142646-6-B
1
2
3
4
6
5
7
1
2
4
5
3-10. Connecting Wire Feeder to Power Source
Make connections as shown. Be
sure connections are tight.
1 14 Pin Control Cord
2 Weld Cable (see Section 3-11
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)
Connectblue to blue and red to red.
5 Red Quick Connect Fitting
(Coolant Return From Gun)
Connectblue to blue and red to red.
6 Work Cable Clamp (see
Section 3-11)
7 Cable Bundle Collar (see
Section 3-11)
Ref. 956142646-4-A

OM-223 839 Page 12
3-11. Changing Cable Between Wire Feeder and XMS 403
!Disconnect power before
changingcables.
1 Access Door
2 Clamp
3 Plastic Collar
Connectweld cable to terminals be-
hind access door.
Remove screws securing door,
clamp and collar. Make cable con-
nections. Reinstall clamp, collar,
and door.
3
2
Tools Needed: 1
Ref. 956142646-4-A
3-12. Installing Wheels On Wire Feeder (Optional)
1 Bar
2 Nut
3 Wheels
4 Screws
Removerubber feet from wire feeder.
Installonly wheels on feeder if smaller
dimensionsare desired, unit will be
used on level floors, or if optional turn-
tableis used.
Installwheels and bars for increased
stability on uneven floors.
12
Tools Needed:
3
4
Ref. 956142646-6-B

OM-223 839 Page 13
SECTION 4 − OPERATION
4-1. Control Panel
1 MIG Gun Connector
2 Red Quick Connect Fitting (Coolant
Return From Gun).
3 Blue Quick Connect Fitting (Coolant
Output To Torch)
4 Remote Control Receptacle
5 Handle
6 Panel
7 D1 − (Display 1)
Displays values and parameters for selected
weldingprocess.
8 D2 − (Display 2)
Displays values and parameters for selected
weldingprocess.
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
1
2
3
4
29
10
28
16 17 18
6
587
9
19
20
21
22
15
14
23
24
25
26
27
11
12
13
Ref. 956142646-5-A

OM-223 839 Page 14
4-2. Switching On Unit And Recalling Factory Parameters
Install power source and wire feeder ac-
cordingto supplied Owner’s Manuals. Turn
On welding power source.
Displays D1 and D2 will show the wire
feedersoftware version.Welding system is
ready to weld with the factory-set default
values, or the values and parameters of the
last weld.
WhenStick or TIG welding, the wire feeder
is energized but does not work. Displays
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
whilewelding.
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. Im-
mediatelypress wire feeder P1 and P3. Re-
lease P1 and P3 when MEM CLR appears
on D1 and D2. Turn power source Off when
DON appears on D1. All parameters will re-
turn to factory default settings the next time
unit is turned on.
4-3. Welding Process Selection
L6
L7
L8
L9
MIG welding selection is made on the pow-
er source. Wire Feeder shows the welding
process selected with four LEDs.
Values and parameters that appear on D1
and D2 are either factory default settings or
last settings entered for the selected pro-
cess.
L6 selection is Manual MIG welding. See
Section4-9.
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).
L7 selection is Synergic MIG welding (non-
pulsed).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 weld-
ing with the same parameter combina-
tion is recommended. When L7 is On
continuously (not flashing), material
transferin the arc is either short circuit
(Short Arc) or by small droplets (Spray
Transfer). Both MIG processes pro-
vide a stable arc and minimum spatter.
L8 selection is Synergic Pulsed MIG weld-
ing. 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 15
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
Synergic Double Pulsed MIG welding to
change when output power is present at
the weld connectors. In Manual MIG, Syn-
ergic MIG, Synergic Pulsed MIG, and Syn-
ergic Double Pulsed MIG welding, press-
ing P1 will change trigger mode, but D1 and
D2 will not change values.
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.
When trigger is pressed a second time,
weldingcontinues 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 se-
lected.
L10
L11
L12
P1
4-5. Setup Menu and Memory Menu Selection
L13 and L14 are generally OFF.
P2 selects the Setup Menu and the ad-
vance programming of MIG welding and to
memorizeand manage personal welding
parametersin 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 er-
rors in the welding parameters and in
the memorized welding parameters.
L13
L14
P2

OM-223 839 Page 16
4-6. Setup Menu
Press P2 to enter SET UP menu.
Setupallows viewing and changing default
parametervalues for all welding processes
for the desired weld characteristics.
D1 shows the welding parameter.
D2 shows the parameter value.
E1 changes the welding parameter.
E2 changes the parameter value.
P2 allows to exit setup Menu and Ad-
vanced Programming and to save the
changedparameters.
.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 pa-
rameters.
4-7. Memory Menu
Press P2 to enter Memory menu.
D1 shows the first free memory position or
the last memory used.
E1 changes the memory position number
from P.01 to P.99.
Any memory position contains all the se-
lectedMIG welding parameters in the Wire
Feederand in the Power Source.
Whena memorized welding point is loaded
the Wire Feeder and the Power Source is
set accordingly.
Verify the Power Source status before
welding,if needed.
D1 shows the memory position.
E1 changes the memory position.
D2 shows the action you can perform on
the memory position.
E2 changes the action on the memory posi-
tion.
WhenD2 shows Ld (load), you can load in
the welder the parameters in the memory
positionselected by D1.
When D2 shows Sto (storage), you can
memorizethe actual welding parameters in
the memory position selected by D1.
WhenD2 shows dEL (delete), you can de-
lete the parameters memorized in the
memoryposition selected by D1.
In order to confirm the action, press P2 until
D1 and D2 flash.
Release P2 and wait until flashing stops.
The action is now performed and the weld-
er exits the Memory menu.
.Do not perform any operation on the
welderwhen in Memory menu to pre-
vent incorrect weld parameters and
poor operation.
4-8. Jog And Purge Selection
.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:
PressingP3 once selects jog. Pressing P8
a second time selects purge.
WhenL15 illuminates, press and hold P3 to
performjog function.
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
weldingarc. Front panel Jog is recom-
mended.
WhenL16 illuminates, press and hold P3 to
performpurge 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.
L15
L16
P3