Miller Electric XR A manual

X R A A n d X R W Processes Description MIG (GMA W) W elding Wire Feeder And Feeder Gun OM-1581 137 532Y 2007 − 01 ™™ Visit our website at www.MillerWelds.com File: MIG (GMA W)[...]

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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

T ABLE OF CONTENTS SECTION 5 − OPERA TION 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Front Panel Controls Of Feeder (Air-Cooled Model Shown) 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Safety Equipment 24 . . . . . [...]

OM-1581 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 in the adjoining symbols. Y Marks a special safety messa[...]

OM-1581 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. 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 (s[...]

OM-1581 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. F [...]

OM-1581 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 .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American W elding Society Standard A WS [...]

OM-1581 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les ut ilisés Sy mbole graphique d’avert iss ement ! Att ention ! Cette pro - cédur e comporte d es r i sques poss ibles[...]

OM-1581 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la peau.[...]

OM-1581 Page 7 2-3 . Dange rs suppléme ntaire s en r e lation avec l’installa tion, le f onctionne ment et l a maintena nce Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l?[...]

OM-1581 Page 8 2-5. Princi pales no rmes de sécurit é Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W eldin[...]

OM-1581 Page 9 SECTION 3 − SPECIFICA TIONS 3-1. Wire Feeder Specifications Specification Description T ype Of Input Power 1 15 V olts AC, 3 Amperes At 50/60 Or 100 Hz Power Control Circuit V oltage Provided At Gun 30 V olts DC Wire Feed Speed Range 70-875 ipm (1.9-22.2 mpm) Overall Dimensions Length: 19 in (483 mm); Width: 9-1/4 in (235 mm); Heig[...]

OM-1581 Page 10 SECTION 4 − INST ALLA TION Be sure that contact tip, liner , and drive rolls are correct for wire size and type. See Section 5 to change parts as needed. See Section 7 for list of other available contact tips. NOTE Review Section 4 -1 through Section 4- 4 to determine how equipment will be connected. Air-cooled models are shown in[...]

OM-1581 Page 1 1 4-2. Connections With A CV Welding Power Source Having Separate 1 15 V AC And Contactor Control Receptacles 1 Constant Voltage (CV) W eld- ing Power Source 2 Plug Obtain matching plugs for connect- ing to power source receptacles. 3 W orkpiece 4 V oltage Sensing Lead Do not connect to workpiece. 5 Gun 6 Wire Feeder 7 1 15 V AC/Cont[...]

OM-1581 Page 12 4-4. Connections With A CC W elding Power Source And A 1 15 V AC/12 VDC Secondary Contactor 1 Constant Current (CC) Weld - ing Power Source 2 W orkpiece 3 V oltage Sensing Lead 4 Gun 5 Wire Feeder 6 3-Conductor 1 15 V AC Cord 7 3-Conductor Contactor Con- trol Cord 8 5-Pin Plug 9 Secondary Contactor 10 Gas Cylinder 1 1 1 15 V AC Plug[...]

OM-1581 Page 13 4-6. Air-Cooled Gun Connections 3 1 Gu n Control Cable Insert plug into Gun Control recep- tacle, and tighten threaded collar . 2 Gas Hose Connect to Gas fitting on feeder . 3 Weld Cable 4 Weld Cable T erminal In Feeder Connect gun weld cable to weld cable terminal in feeder . 5 Wire Conduit 6 Thumbscrew 7 Wire Conduit Block 8 Strai[...]

OM-1581 Page 14 4-7. W ater-Cooled Gun Connections 1 Gas Hose Connect to Gas fitting on feeder . 2 Water Hose Connect to water to gun fitting on feeder (left-hand threads). 3 Wire Conduit 4 Thumbscrew 5 Wire Conduit Block Loosen thumbscrew , and insert conduit through Wire opening until it bottoms against block. Trim liner if necessary , as close t[...]

OM-1581 Page 15 4-8. Air-Cooled Feeder Connections 1 Gas Hose Grommet 2 10 ft (3 m) Gas Hose 3 Rear Of Gas Fitting Route one end of gas hose through grommet, and connect hose to rear of Gas fitting in feeder . Connect remaining end of hose to regulator/flowmeter . 4 Weld Cable T o Welding Power Source Select and prepare weld cable ac- cording to we[...]

OM-1581 Page 16 4-9. W ater-Cooled Feeder Connections Obtain coolant supply . 1 Gas Hose Grommet 2 10 ft (3 m) Gas Hose 3 Rear Of Gas Fitting Route one end of gas hose through grommet, and connect hose to rear of Gas fitting in feeder . Connect remaining end of hose to regulator/flowmeter . 4 Coolant Supply Hose Grommet 5 10 ft (3 m) Water Supply H[...]

OM-1581 Page 17 4-10. V oltage Sensing Lead Connections Unit is factory set for constant volt- age (CV) welding. T o set unit for constant current (CC) welding, proceed as follows: 1 T erminal Strip 2T 2 Strain Relief Loosen screws of strain relief. 3 V oltage Sensing Lead Route ring terminal end of lead through strain relief, and connect ring term[...]

OM-1581 Page 18 4-1 1. 1 15 V AC/Contactor Control Plug Information 1 Interconnecting Cord 2 1 15 V AC/Contactor Control Plug PLG5 If CC or CC/CV welding power source is equipped with matching 14-socket receptacle, insert plug, and tighten threaded collar . Proceed to Section 4-13 . If plug PLG5 will not connect to CC welding power source receptacl[...]

OM-1581 Page 19 4-12. Replacing 1 15 V AC/Contactor Control Plug With Customer-Supplied 5-Pin Or T wistlock Plug 1 1 15 V AC/Contactor Control Plug PLG5 2 Contactor Control Cord 3 1 15 V AC Cord Find and label cords by following leads to back of PLG5: Contactor control cord connects to pins A & B of PLG5 1 15 V AC cord connects to pin J of PLG5[...]

OM-1581 Page 20 4-13. Installing Wire Spool T urn Off wire feeder and welding power source. 1 Wire Spool 2 T op Cover 3 Pressure Roll Assembly 4 Gun Contact Tip If wire spool is being replaced, open pressure roll assembly in gun, and cut welding wire off at contact tip. For welding power sources without contactor , retract wire onto spool. For weld[...]

OM-1581 Page 21 4-14. Threading W elding Wire Through Feeder 1 Wire Spool Loosen wire from spool, cut off bent wire, and pull 6 in (150 mm) of wire of f spool. 2 T ension Arm 3 Mounting Arm T o open pressure roll assembly , open tension arm and lift mounting arm. 4 Wire Inlet Guide 5 Drive Roll 6 Wire Conduit Fitting Thread wire through wire inlet [...]

OM-1581 Page 22 4-15. Threading W elding Wire Through Gun 1 Pressure Roll Assembly Lift arm and open pressure roll assembly . 2 Wire Conduit Lay wire conduit out straight. 3 Jog Switch Push Jog switch up to feed wire through wire conduit. 4 Drive Roll Fo r wire sizes .035 in (0.9 mm) and smaller use small groove, and .047 in (1.2 mm) and 1/16 in (1[...]

OM-1581 Page 23 4-17. Adjusting Wire Feed Starting Speed 1 2 T op Of PC1 Ref. 151 772-B / Ref. 142 054-B T o adjust wire feed starting speed, proceed as follows: T urn Of f wire feeder and welding power source. Open right side panel. 1 Motor Speed Control Board PC1 2 Motor Start Control Potentiometer R70 T urn potentiometer clockwise to increase ti[...]

OM-1581 Page 24 SECTION 5 − OPERA TION 5-1. Front Panel Controls Of Feeder (Air-Cooled Model Shown) 1 V oltage/Wire Speed Meter (Optional) 2 V oltage/Wire Speed Switch (Optional) 3 Run-In Speed Control 4 Jog Switch 5 Burnback T ime Control (Optional) 6 Spot/Continuous Switch (Optional) 7 Remote V oltage Control (Optional) 8 Power Switch 9 Time Ra[...]

OM-1581 Page 25 5-4. Run-In Speed Control 1 Run-In Speed Control Use control to set wire feed speed before arc initiation. After arc initiation, wire feed speed is controlled by the Wire Speed Control on the welding gun (see Section 5-12 ). Th e scale around the control is per- cent of full range, not wire speed. As a general rule, set run-in speed[...]

OM-1581 Page 26 5-7. Spot Controls (Optional) 1 Spot/Continuous Switch Use switch to select either an un- timed continuous weld cycle or a timed spot weld cycle. Both weld cycles consist of the following steps: run-in, weld (untimed or spot time), and burnback. 2 Time Range Switch Use switch to select spot weld time range. 3 Spot Time Control Use c[...]

OM-1581 Page 27 5-10. Flowmeter (Optional) CAUTION Wire feeding system is designed for maximum of 50 psi (345 kPa) gas pressure. • Be sure that regulator/flowmeter has preset conditions of no more than 50 psi (345 kPa) gas pressure. 1 Flowmeter 2 V alve Use flowmeter to control shielding ga s flow at the feeder . The scale o n the flowmeter is in[...]

OM-1581 Page 28 5-12. Gun Controls 1 Gun T rigger Press trigger to energize welding power source contactor (if applica- ble), start shielding gas flow , and begin wire feed. Fo r shielding gas preflow and post- flow , partially press trigger before and partially release after welding. 2 Wire Speed Control Use control to adjust wire feed speed. The [...]

OM-1581 Page 29 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance T urn Off all power before maintaining. 3 Months OR Blow Out Or V acuum Inside Replace Unreadable Labels 6 Months Clean Drive Rolls 5-2 Clean And T ighten W eld T erminals 4-8 3 Months − − See Section 7 T ape Or Replace Cracked W eld Cable − − 14-Pin Co[...]

OM-1581 Page 30 6-2. Changing Or Cleaning Gun Drive Roll T urn Off wire feeder and welding power source. 1 T op Cover 2 Pressure Roll Assembly Cut of f wire where it enters pressure roll assembly area. 3 Setscrew 4 Current Pick-Up T ab This tab helps prevent burnback caused by welding arcs inside the contact tip. This tab may be re- moved to provid[...]

OM-1581 Page 31 6-3. Changing Feeder Drive Roll And Wire Inlet Guide T urn Off wire feeder and welding power source. Lay wire conduit o ut straight. Open gun pressure roll assembly , and cut welding wire off at contact tip. 1 Pressure Roll Assembly 2 Wire Spool For welding power sources without contactor , retract wire onto spool. For welding power[...]

OM-1581 Page 32 6-4. Replacing Or Cleaning Gun Drive Roll Bearing T urn Off wire feeder and welding power source. 1 T op Cover 2 Pressure Roll Assembly 3 Screw 4 Pressure Roll Remove as shown. Use a wire brush to clean bearing. Reinstall with washers, and tighten screw . Close pressure roll assembly . Reinstall top cover . Ref. 151 599 − F 1 2 3 [...]

OM-1581 Page 33 6-6. Changing Gun Contact T ip Ref. 150 437-A 2 1 Remove nozzle 1 Nozzle 2 FasT ip Unscrew FasTip. Install new FasTip. 6-7. Removing Diffuser In Air And W ater-Cooled Pistol-Grip Guns W A TER IN GUN P ARTS can cause ELECTRIC SHOCK and can lower weld quality . • Turn Off welding power source and water supply before working on gun. [...]

OM-1581 Page 34 6-8. Replacing The Liner Y T urn Off welding power source and wire feeder . 1 Drive Roll 2 Collet Nut La y gun cable out straight. Remove drive roll on gun and collet nut on on both ends of liner tube assembly and remove old liner . 3 New Liner Insert split end of new liner into liner tube assembly and continue feed- ing liner throu[...]

OM-1581 Page 35 6-9. Replacing Hub Assembly T urn Off wire feeder and welding power source. Remove gun top cover and open pressure roll assembly as shown in Section 6-4. Retract wire onto spool and remove spool. T ake hub apart as shown. 1 Met al Brak e Washer 2 Flat W asher 3 Brake Washer 4 Hub 5 Keyed Washer 6 Spring 7 Cap Screw 8 Retaining Ring [...]

OM-1581 Page 36 6-10. Adjusting Hub T ension Turn On welding power source and wire feeder to make this adjustment. 1 Wire Speed Control Adjust control to wire speed for welding. 2 Jog Switch Push up, and then release Jog switch. Hub tension is okay if wire unwinds freely , but wire does not backlash when Jog switch is released. 3 Cap Screw T urn ca[...]

OM-1581 Page 37 6-13. T roubleshooting A. Wire Feeder T rouble T rouble Remedy Pressing gun trigger does not energize feeder . Welding wire is not energized. Shielding gas flows. Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 4-6). Secure 1 15 V AC input plug connection (see Section 4-1 1). Check fuse F1 (see [...]

OM-1581 Page 38 B. Gun Trouble T rouble Remedy No weld output; gun/feeder does not work. Secure 1 15 V AC input plug in 1 15 volts ac receptacle (see Section 4- 1 1). Place Power switch on welding power source in the On position. Erratic weld output. Tighten and clean all connections. Pressing gun/feeder trigger does not en- ergize weld control; we[...]

OM-1581 Page 39 SECTION 7 − ELECTRICAL DIAGRAMS Figure 7-1. Circuit Diagram For Wire Feeder 156 399-C[...]

OM-1581 Page 40 195 712-B Figure 7-2. Circuit Diagram For Gun[...]

OM-1581 Page 41 Notes[...]

OM-1581 Page 42 SECTION 8 − P ARTS LIST 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 17 19 20 21 22 23 24 25 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 60 59 61 62 71 Fig 8-2 72 73 74 75 76 77 78 79 Figure 8-1. Main Assembly Fig 8-3 63 64 65 66 67 70 68 69 41 40 PC1 PC3 . Hardware is common and[...]

OM-1581 Page 43 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 089 572 Catch, Link-lock 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 12 167 Insulator , Door 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-1581 Page 44 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly (Continued) Quantity 50 1 1 1 152 Skid, Base 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 +176 714 Cabinet, Control 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-1581 Page 45 Description Part No. Dia. Mkgs. Item No. Figure 8-2. Motor & Wire Drive (Fig 8-1 Item 71) Quantity 1 1 15 191 Drive Assembly , Wire (Consisting Of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 058 968 Ring, Retainer E 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-1581 Page 46 1 2 3 4 5 6 7 8 See Fig 8-1 Item 59 10 12 13 14 15 16 17 18 19 20 21 22 23 9 11 PC2 PC4 . Hardware is common and not available unless listed. 145 127-B Figure 8-3. Panel, Front w/Components (W ater-Cooled Model Illustrated)[...]

OM-1581 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 8-3. Panel, Front w/Components (Fig 8-1 Item 59) Quantity 1 ♦ 1 1 1 569 Meter , Flow 6-60 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦ 1 1 1 633 Guard, Flow Meter 1 . . . . . . . . . . . . [...]

OM-1581 Page 48 Figure 8-4. Exploded View Of Gun *Includes Items 24 & 37 . Hardware is common and not available unless listed. 803 706-C 38(Fig. 8-5) 47 46 45 44 50 30 48 51 52 1 27 37 36 35 34 29 41 39* 40 12 13 54 11 28 22 23 55 14 14 30 26 25 20 21 56 15 16 17 19 18 53 8 3 4 5 6 10 9 6 7 43 42 24[...]

OM-1581 Page 49 Description Part No. Dia. Mkgs. Item No. Figure 8-4. Exploded View Of Gun Quantity 1 214 745 Cover 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-1581 Page 50 Description Part No. Dia. Mkgs. Item No. Figure 8-4. Exploded View Of Gun (Continued) Quantity 25 1 12 896 Spring, Cprsn .240 Od X .020 Wire X .437 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 135 773 Knob, Thumb T ension Adjusting 8-32 1 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-1581 Page 51 Ref. 800 434-G . Hardware is common and not available unless listed. 1 2 5 3 4 6 7 8 17 9 10 17 11 12 1 2 3 4 13 14 15 8 16 Figure 8-5. Head T ube Assembly Of Pistol-Grip Gun Item No. Part No. Quantity Description Figure 8-5. Head T ube Assembly Of Pistol-Grip Gun (Figure 8-4 Item 15) 1 199 613 Nozzle, Brass 5/8 In Orifice T apered [...]

OM-1581 Page 52 SECTION 9 − P ARTS LIST INCLUDING CONSUMABLES Item Number 12 3 4 5 Ref. 803 909-A / 803 932 / 803 933 / 803 934 6.0” STRAIGHT (#221 087) 6.0” STRAIGHT (#221 519) .030 − 1/16” WIRE .030 − 1/16” WIRE .035 − 1/16” WIRE .030 − 1/16” WIRE (231 512) (227 749) (231 51 1) XR-A Spoolmatic Barrel Assy XR-W Barrel Assy (#[...]

OM-1581 Page 53 Description Part No. Item No. Figure 9-1. Consumables Flowchart Quantity T able 9-1. Nozzles 1 ♦ 176238 Nozzle, Spot Flat (Requires Dif fuser 209099, Used With Any . . . . . . . . . . . . . . Heavy Duty FasT ip t Contact T ip) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 176240 Nozzle, Spot Ins[...]

OM-1581 Page 54 Description Part No. Item No. Figure 9-1. Consumables Flowchart (Continued) Quantity T able 9-5. V alue Multi − T urn Contact Tips* 2 ♦ 071 825 .030 in (0.9 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦ 054 202 .035 in (0.9 mm) 1 . . [...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe[...]

PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 9 20-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters −[...]