ISO 9001:2000 Quality System Standard. 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.
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.
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.
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...
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints.
LES RAYONS D’ARC peuvent entraî- ner des brûlures aux yeux et à la peau. 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.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 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’installation électrique −...
2-5. Principales normes de sécurité Safety in Welding, 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 for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
SECTION 4 − INSTALLATION NOTE 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. Review Section 4-1 through Section 4-4 to determine how equipment will be connected. Air-cooled models are shown in Section 4-1 through Section 4-4.
4-2. Connections With A CV Welding Power Source Having Separate 115 VAC And Contactor Control Receptacles 4-3. Connections With A CC Welding Power Source Having A Contactor Control Receptacle Obtain matching plugs for connect- ing to power source receptacles. Do not connect to workpiece. 10 115 VAC Plug Obtain plug for wire feeder.
4-4. Connections With A CC Welding Power Source And A 115 VAC/12 VDC Secondary Contactor 4-5. Removing Top Cover Of Pistol Grip Gun OM-1581 Page 12 Constant Current (CC) Weld- ing Power Source Workpiece Voltage Sensing Lead Wire Feeder 3-Conductor 115 VAC Cord 3-Conductor Contactor Con- trol Cord 5-Pin Plug...
4-6. Air-Cooled Gun Connections Left Side Gun Control Cable Insert plug into Gun Control recep- tacle, and tighten threaded collar. Gas Hose Connect to Gas fitting on feeder. Weld Cable Weld Cable Terminal In Feeder Connect gun weld cable to weld cable terminal in feeder.
4-7. Water-Cooled Gun Connections OM-1581 Page 14 Left Side Tools Needed: 5/8, 1-1/8 in Gas Hose Connect to Gas fitting on feeder. Water Hose Connect to water to gun fitting on feeder (left-hand threads). Wire Conduit Thumbscrew Wire Conduit Block Loosen thumbscrew, and insert conduit through Wire opening until it bottoms against block.
4-8. Air-Cooled Feeder Connections Rear Panel Connect To Positive (+) Weld Output Terminal On Welding Power Source Top View Connect To Regulator/ Flowmeter Gas Hose Grommet 10 ft (3 m) Gas Hose Rear Of Gas Fitting Route one end of gas hose through grommet, and connect hose to rear of Gas fitting in feeder.
4-9. Water-Cooled Feeder Connections Connect To Positive (+) Weld Return Fitting On Output Terminal On Coolant Supply Welding Power Source OM-1581 Page 16 Top View Rear Panel Connect To Connect To Connect To Supply Fitting On Regulator/ Coolant Supply Flowmeter Obtain coolant supply.
4-10. Voltage Sensing Lead Connections 3 2 1 Tools Needed: 1/4 in E D C B A Unit is factory set for constant volt- age (CV) welding. To set unit for constant current (CC) welding, proceed as follows: Terminal Strip 2T Strain Relief Loosen screws of strain relief.
4-11. 115 VAC/Contactor Control Plug Information Pin* Remote Contactor Remote Voltage Control *The remaining pins are not used. OM-1581 Page 18 Pin Information A, B Contact closure to A completes contactor control circuit. 115 volts ac. Contact closure to I completes 115 volts ac contactor control circuit. Circuit common for 115 volts ac circuit.
4-12. Replacing 115 VAC/Contactor Control Plug With Customer-Supplied 5-Pin Or Twistlock Plug Tools Needed: 115 VAC/Contactor Control Plug PLG5 Contactor Control Cord 115 VAC Cord Find and label cords by following leads to back of PLG5: Contactor control cord connects to pins A &...
4-13. Installing Wire Spool Tools Needed: OM-1581 Page 20 Turn Off wire feeder and welding power source. Wire Spool Top Cover Pressure Roll Assembly Gun Contact Tip If wire spool is being replaced, open pressure roll assembly in gun, and cut welding wire off at contact tip.
4-14. Threading Welding Wire Through Feeder Tools Needed: Wire Spool Loosen wire from spool, cut off bent wire, and pull 6 in (150 mm) of wire off spool. Tension Arm Mounting Arm To open pressure roll assembly, open tension arm and lift mounting arm.
4-15. Threading Welding Wire Through Gun WOOD 4-16. Coolant Guidelines CAUTION INCORRECT COOLANT OR COOLANT CONTAINING STOP-LEAK ADDITIVES can corrode and/or plug gun/feeder cooling passages. Use only a mix of 50% distilled water and 50% high quality automotive antifreeze as proper coolant for this product. Do not use antifreeze containing stop-leak additives.
4-17. Adjusting Wire Feed Starting Speed Tools Needed: Nonconductive 1/4 in To adjust wire feed starting speed, proceed as follows: Turn Off wire feeder and welding power source. Open right side panel. Motor Speed Control Board Motor Start Control Potentiometer R70 Turn potentiometer clockwise to increase time it takes the motor to ramp up to speed.
SECTION 5 − OPERATION 5-1. Front Panel Controls Of Feeder (Air-Cooled Model Shown) 5-2. Safety Equipment 5-3. Work And Voltage Sensing Cable Clamps Tools Needed: OM-1581 Page 24 Voltage/Wire Speed Meter (Optional) Voltage/Wire Speed Switch (Optional) Run-In Speed Control Jog Switch Burnback Time Control (Optional) Spot/Continuous Switch...
5-4. Run-In Speed Control 5-5. Jog Switch 5-6. Voltage/Wire Speed Switch And Meter (Optional) Volt sensing lead must be con- nected to workpiece for me- ters to operate. 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...
5-7. Spot Controls (Optional) 5-8. Remote Voltage Control (Optional) 5-9. Power Switch OM-1581 Page 26 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.
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. 5-11. Internal Controls BRAKE RELEASE LOW TORQUE HIGH TORQUE Flowmeter...
5-12. Gun Controls 5-13. Shielding Gas 5-14. Coolant Supply For Water-Cooled Models Only 5-15. Sequence Of Gas Metal Arc Welding (GMAW) − Continuous Or Spot Install & Put On Connect Personal Safety Equipment Equipment OM-1581 Page 28 Turn On Gas Set Controls And Water (If Applicable)
6-2. Changing Or Cleaning Gun Drive Roll Tools Needed: 5/64 in OM-1581 Page 30 Turn Off wire feeder and welding power source. Top Cover Pressure Roll Assembly Cut off wire where it enters pressure roll assembly area. Setscrew Current Pick-Up Tab This tab helps prevent burnback caused by welding arcs inside the contact tip.
6-3. Changing Feeder Drive Roll And Wire Inlet Guide Tools Needed: 5/16 in Turn Off wire feeder and welding power source. Lay wire conduit out straight. Open gun pressure roll assembly, and cut welding wire off at contact tip. Pressure Roll Assembly Wire Spool For welding power sources without contactor, retract wire onto spool.
6-4. Replacing Or Cleaning Gun Drive Roll Bearing 6-5. Replacing Or Cleaning Feeder Drive Roll Bearing Tools Needed: OM-1581 Page 32 Turn Off wire feeder and welding power source. Top Cover Pressure Roll Assembly Screw Pressure Roll Remove as shown. Use a wire brush to clean bearing.
6-6. Changing Gun Contact Tip 6-7. Removing Diffuser In Air And Water-Cooled Pistol-Grip Guns WARNING WATER IN GUN PARTS can cause ELECTRIC SHOCK and can lower weld quality. Turn Off welding power source and water supply before working on gun. Stop engine on welding generators. Always point gun downward when removing water-cooled barrel to keep water out of gun parts.
6-8. Replacing The Liner Split End OM-1581 Page 34 Y Turn Off welding power source and wire feeder. Drive Roll Collet Nut Lay gun cable out straight. Remove drive roll on gun and collet nut on on both ends of liner tube assembly and remove old liner.
6-9. Replacing Hub Assembly Tools Needed: 7/16 in Turn 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. Take hub apart as shown. Metal Brake Washer Flat Washer Brake Washer...
6-10. Adjusting Hub Tension Tools Needed: 7/16 in 6-11. Overload Protection 6-12. Water Flow Switch (Optional For Water-Cooled Models) The water flow switch protects the gun from overheating. If coolant flow rate drops below 1 qt/min, the water flow switch opens and stops the welding wire from feeding. See Section 6-13 for remedies to this trouble. OM-1581 Page 36 Push And Turn Pull Out And Replace F1...
6-13. Troubleshooting A. Wire Feeder Trouble Trouble Pressing gun trigger does not energize Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 4-6). feeder. Welding wire is not energized. Shielding gas flows. Secure 115 VAC input plug connection (see Section 4-11). Check fuse F1 (see Section 6-11).
B. Gun Trouble Trouble No weld output; gun/feeder does not Secure 115 VAC input plug in 115 volts ac receptacle (see Section 4-11). work. 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- Secure plug from gun control cable into 10-socket receptacle on wire feeder (see Section 4-6).
SECTION 8 − PARTS LIST Hardware is common and not available unless listed. This main assembly drawing shows the XR-W (water-cooled model). Some parts for the XR-A (air-cooled model) vary in appearance. When differences occur, they are called out in the part description.
Hardware is common and not available unless listed. Figure 8-5. Head Tube Assembly Of Pistol-Grip Gun Item Part Figure 8-5. Head Tube Assembly Of Pistol-Grip Gun (Figure 8-4 Item 15) ... . . 199 613 Nozzle, Brass 5/8 In Orifice Tapered .
Item Part Figure 9-1. Consumables Flowchart ... . 176238 Nozzle, Spot Flat (Requires Diffuser 209099, Used With Any Heavy Duty FasTipt Contact Tip) ... . 176240 Nozzle, Spot Inside Corner (Requires Diffuser 209099, Used With Any Heavy Duty FasTipt Contact Tip)
Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.
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. 2007 Miller Electric Mfg. Co. 2007−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...