Miller Electric XR A Owner's Manual
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Miller Electric XR A Owner's Manual

Miller Electric XR A Owner's Manual

Wire feeder and feeder gun
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OM-1581
137 532Y
2007−01
Processes
MIG (GMAW) Welding
Description
Wire Feeder And Feeder Gun
XR A And XR W
File: MIG (GMAW)
Visit our website at
www.MillerWelds.com

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  • Page 1 OM-1581 137 532Y 2007−01 Processes MIG (GMAW) Welding Description Wire Feeder And Feeder Gun XR A And XR W File: MIG (GMAW) Visit our website at www.MillerWelds.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 TABLE OF CONTENTS SECTION 5 − OPERATION ..............5-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    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.
  • Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    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.

  • Page 8: Principal Safety Standards

    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...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    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.
  • Page 10 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.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    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 −...

  • Page 12: Principales Normes De Sécurité

    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).

  • Page 13: Section 3 − Specifications

    SECTION 3 − SPECIFICATIONS 3-1. Wire Feeder Specifications Specification Type Of Input Power Control Circuit Voltage Provided At Gun Wire Feed Speed Range Overall Dimensions Maximum Spool Capacity Cooling Method Weight (Feeder With Gun) 3-2. Gun Specifications Specification Input Voltage Duty Cycle (Air-Cooled Models) Duty Cycle (Water-Cooled Models) Wire Size Range...

  • Page 14: Section 4 − Installation

    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.

  • Page 15: Connections With A Cv Welding Power Source Having Separate 115 Vac And Contactor Control Receptacles

    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.

  • Page 16: Connections With A Cc Welding Power Source And A 115 Vac/12 Vdc Secondary Contactor

    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...

  • Page 17: Air-Cooled Gun Connections

    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.

  • Page 18: Water-Cooled Gun Connections

    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.

  • Page 19: Air-Cooled Feeder Connections

    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.

  • Page 20: Water-Cooled Feeder Connections

    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.

  • Page 21: Voltage Sensing Lead Connections

    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.

  • Page 22: 115 Vac/Contactor Control Plug Information

    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.

  • Page 23: Replacing 115 Vac/Contactor Control Plug With Customer-Supplied 5-Pin Or Twistlock Plug

    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 &...

  • Page 24: Installing Wire Spool

    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.

  • Page 25: Threading Welding Wire Through Feeder

    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.

  • Page 26: Threading Welding Wire Through Gun

    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.

  • Page 27: Adjusting Wire Feed Starting Speed

    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.

  • Page 28: Section 5 − Operation

    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...

  • Page 29: Run-In Speed Control

    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...

  • Page 30: Spot Controls (Optional)

    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.

  • Page 31: Flowmeter (Optional)

    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...

  • Page 32: Gun Controls

    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)

  • Page 33: Section 6 − Maintenance & Troubleshooting

    SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance 3 Months Replace Unreadable Labels Section Clean Tighten Weld Terminals Turn Off all power before maintaining. 3 Months Tape Or Replace Cracked Weld − − Cable Replace Cracked Parts − − 14-Pin Cord Gas Hose Gun Cable...

  • Page 34: Changing Or Cleaning Gun Drive Roll

    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.

  • Page 35: Changing Feeder Drive Roll And Wire Inlet Guide

    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.

  • Page 36: Replacing Or Cleaning Gun Drive Roll Bearing

    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.

  • Page 37: Changing Gun Contact Tip

    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.

  • Page 38: Replacing The Liner

    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.

  • Page 39: Replacing Hub Assembly

    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...

  • Page 40: Adjusting Hub Tension

    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...

  • Page 41: Troubleshooting

    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).
  • Page 42 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).

  • Page 43: Section 7 − Electrical Diagrams

    SECTION 7 − ELECTRICAL DIAGRAMS 156 399-C Figure 7-1. Circuit Diagram For Wire Feeder OM-1581 Page 39...
  • Page 44 195 712-B Figure 7-2. Circuit Diagram For Gun OM-1581 Page 40...
  • Page 45 Notes OM-1581 Page 41...

  • Page 46: Section 8 − Parts List

    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.
  • Page 47 Item Dia. Part Mkgs....089 572 ....112 167 ....134 327 .
  • Page 48 Item Dia. Part Mkgs....111 152 ... . . +176 714 ....153 901 .
  • Page 49 Item Dia. Part Mkgs....115 191 ....058 968 .
  • Page 50 Hardware is common and not available unless listed. Figure 8-3. Panel, Front w/Components (Water-Cooled Model Illustrated) OM-1581 Page 46 See Fig 8-1 Item 59 145 127-B...
  • Page 51 Item Dia. Part Mkgs....111 569 ....111 633 .
  • Page 52 Hardware is common and not available unless listed. 803 706-C Figure 8-4. Exploded View Of Gun OM-1581 Page 48...
  • Page 53 Item Dia. Part Mkgs. Figure 8-4. Exploded View Of Gun ... . . 214 745 Cover ... . . Deleted .
  • Page 54 Item Dia. Part Mkgs. Figure 8-4. Exploded View Of Gun (Continued) ... . 112 896 Spring, Cprsn .240 Od X .020 Wire X .437 ... . 135 773 Knob, Thumb Tension Adjusting 8-32 .
  • Page 55 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 .

  • Page 56: Section 9 − Parts List Including Consumables

    SECTION 9 − PARTS LIST INCLUDING CONSUMABLES Item Number .030−1/16” WIRE Figure 9-1. Consumables Flowchart For XR-A And XR-W Pistol Guns OM-1581 Page 52 .030−1/16” WIRE .030−1/16” WIRE .035−1/16” WIRE (231 512) (227 749) (231 511) STANDARD INSULATOR COLLARED XR-A Spoolmatic INSULATOR Barrel Assy (#232 284)
  • Page 57 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)
  • Page 58 Item Part Figure 9-1. Consumables Flowchart (Continued) ... 071 825 .030 in (0.9 mm) ... 054 202 .035 in (0.9 mm) .
  • Page 59 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.
  • Page 60 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...

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