Miller Electric XR Control Owner's Manual
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Miller Electric XR Control Owner's Manual

Air- and water-cooled guns
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OM-1594
181 715Z
May 2005
Processes
MIG (GMAW) Welding
Description
Wire Feeder And Feeder Gun
XR Control
XR Air- And Water-Cooled Guns
Visit our website at
www.MillerWelds.com

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  • Page 1 OM-1594 181 715Z May 2005 Processes MIG (GMAW) Welding Description Wire Feeder And Feeder Gun XR Control XR Air- And Water-Cooled Guns 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 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Feeder Drive Assembly Maintenance 7-2. Gun Drive Assembly Maintenance For An XR-Edge Gun 7-3. Replacing Head Tube Liner In XR-Edge Guns 7-4. Replacing The Liner ..............7-5.
  • Page 5 Declaration of Conformity for European Community (CE) Products Note This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA XR-Control...

  • Page 7: 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 8 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 9: 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 10: 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 11: Section 2 − Consignes De Sécurité − À 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 12 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 13: Proposition Californienne 65 Avertissements

    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 14: 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 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions S-178 936 A. Warning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. Welding wire and drive parts are at welding voltage during operation −...

  • Page 16: Rating Label For Ce Products

    3-2. Rating Label For CE Products OM-1594 Page 10 S/N: 50/60 50/60 IP 23 X 100 % Read the Owner’s Manual. Do not overtighten wire spool brake pressure. Tighten only until wire does not overspool from wire supply spool. Do not overtighten drive roll pressure.

  • Page 17: Symbols And Definitions

    3-3. Symbols And Definitions Note Some symbols are found only on CE products. Amperes Degree Of Protection Press To Set Purge Burnback Time Primary Current Water (Coolant) Output SECTION 4 − INTRODUCTION 4-1. Specifications Type of Input Welding Power Power Source Type Constant Voltage (CV) DC For GMAW Or...

  • Page 18: Duty Cycle And Overheating

    4-2. Duty Cycle And Overheating 100% Duty Cycle At 200 Amperes Using Argon Continuous Welding OM-1594 Page 12 Air-Cooled Models 60% Duty Cycle At 250 Amperes Using Argon 6 Minutes Welding Water-Cooled Models 100% Duty Cycle At 400 Amperes Using Argon Continuous Welding Duty Cycle is percentage of 10 min- utes that unit can weld at rated load...

  • Page 19: Section 5 − Installation

    SECTION 5 − INSTALLATION NOTE Be sure that contact tip, liner, and drive rolls are correct for wire size and type. See Parts List to change parts as needed. NOTE Many procedures apply to both guns covered in this manual. Where procedures differ, separate instructions are given.

  • Page 20: Air-Cooled Feeder Connections

    5-2. Air-Cooled Feeder Connections Rear Panel Connect To 14-Socket Receptacle On Welding Power Source Connect To Positive (+) Weld Output Terminal On Welding Power Source OM-1594 Page 14 Top View Gas Fitting Route one end of 10 ft (3 m) gas hose to rear of unit, and connect hose to gas solenoid fitting.

  • Page 21: Air-Cooled Gun Connections

    5-3. Air-Cooled Gun Connections Left Side Gun Control Cable Insert plug into Gun Control receptacle, and tighten threaded collar. Gas Hose Reed Relay Weld Cable Weld Cable Terminal In Feeder Route weld cable from welding power source through reed relay to weld cable terminal in feeder and connect to weld cable terminal.

  • Page 22: Water-Cooled Feeder Connections

    5-4. Water-Cooled Feeder Connections Rear Panel Connect To 14-Socket Receptacle On Welding Power Source Connect To Positive (+) Weld Output Terminal On Welding Power Source GTAW Or Where Application HF* Is Used MILLER Low Conductivity Coolant No. 043 810** Coolant *HF: High Frequency Current **MILLER coolants protect to -37 F (-38 C) and resist algae growth.

  • Page 23: Water-Cooled Gun Connections

    5-5. Water-Cooled Gun Connections Tools Needed: 9/16 in Left Side Gun Control Cable Insert plug into Gun Control receptacle, and tighten threaded collar. Gas Hose Reed Relay Weld Cable Weld Cable Terminal In Feeder Route weld cable from welding power source through reed relay to weld cable terminal in feeder and connect to weld cable terminal.

  • Page 24: 14-Pin Plug Information

    5-6. 14-Pin Plug Information Pin* *The remaining pins are not used. 5-7. (Optional) Voltage Sensing Lead Connections And CC/CV Jumper Plug Settings Tools Needed: 1/4 in OM-1594 Page 18 Pin Information 24 volts ac with respect to socket G. Contact closure to A completes 24 volts ac contactor control circuit. Circuit common for 24 volts AC circuit.

  • Page 25: Meter Circuit Board Settings

    5-8. Meter Circuit Board Settings X Means switch position does not affect specified function. Means switch must be in this position. Switch settings from the factory. For sense lead, connect PLG51 to PLG50. Before feeder can be used with a power source that does not support pins F and H, a voltage sensing lead must be installed in feed- er.

  • Page 26: Opening Top Cover Of Xr-Edge Gun

    5-9. Opening Top Cover Of XR-Edge Gun 5-10. Removing Top Cover Of Pistol Grip Gun OM-1594 Page 20 Top Cover Squeeze sides of cover to release clips and lift up as shown. To close cover, pivot cover closed on gun, and push cover down until clips lock tight.

  • Page 27: Installing Wire Spool

    5-11. Installing Wire Spool Wire Spool Top Cover Pressure Roll Assembly Gun Contact Tip If wire spool is being replaced, open top cover, open pressure roll as- sembly in gun, and cut welding wire off at contact tip. Retract wire onto spool. Hub Pin Notch Compression Spring (Optional...

  • Page 28: Threading Welding Wire Through Feeder

    5-12. Threading Welding Wire Through Feeder Tools Needed: Open tension arm. Thread wire thru inlet guide, along drive roll groove, and into wire conduit. Close tension arm. Adjust tension as follows: grasp spool with one hand, press Jog switch, and turn thumb nut clockwise until motor stalls when Jog switch is pressed.

  • Page 29: Threading Welding Wire Through Gun

    5-13. Threading Welding Wire Through Gun For XR-Edge Gun: Welding wire is electrically live when gun trigger is used to jog wire. Turn OFF coolant supply before removing head tube on water-cooled gun. Lay gun cable out straight. Open top cover, and open pressure roll assembly.

  • Page 30: Adjusting Wire Feed Starting Speed

    5-14. Adjusting Wire Feed Starting Speed Tools Needed: Nonconductive 1/4 in OM-1594 Page 24 To adjust wire feed starting speed, proceed as follows: Remove protective white rubber cap before making adjustment. Adjust potentiometer using a small nonconductive screwdriver. Turn potentiometer increase time it takes the motor to ramp up to speed.

  • Page 31: Setting Switches For Preflow And Postflow

    5-15. Setting Switches For Preflow And Postflow Tools Needed: Nonconductive 1/4 in To set switches for preflow and postflow, proceed as follows: To provide a 3.5 second preflow time, use a small nonconductive screwdriver to set switch S1-1 in the up position. To turn preflow time off, set S1-1 in the down position.

  • Page 32: Adjusting Trigger Hold Actuation Time

    5-16. Adjusting Trigger Hold Actuation Time Tools Needed: Nonconductive 1/4 in OM-1594 Page 26 To adjust trigger hold actuation time, proceed as follows: To decrease trigger hold actuation time, use a small nonconductive screwdriver potentiometer increase actuation time, rotate potentiometer counterclockwise. Reinstall side panel.

  • Page 33: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Controls Voltage/Wire Speed Meter Voltage/Wire Speed Switch When switch is in Voltage position, and operator is welding, meter displays arc voltage. Cable resistance poor connections may cause displayed voltage to vary slightly from actual voltage at welding arc.

  • Page 34: Internal Controls

    6-2. Internal Controls OM-1594 Page 28 Open left side door. Run-In Speed Control Use this control to set run-in wire feed speed before arc initiation. After arc initiation, weld wire feed speed is controlled by the wire speed setting on the welding gun (see Section 6-3).

  • Page 35: Gun Controls

    6-3. Gun Controls 6-4. Shielding Gas 6-5. Coolant Supply For Water-Cooled Models Only Trigger Press trigger to energize welding power source contactor applicable), start shielding gas flow, and begin wire feed. Switches inside the wire feeder can be set to provide timed shielding gas preflow and postflow when trigger is pressed and released (see Section 5-15).

  • Page 36: Sequence Of Gas Metal Arc Welding (Gmaw) − Continuous Or Spot

    6-6. Sequence Of Gas Metal Arc Welding (GMAW) − Continuous Or Spot Install & Put On Connect Personal Safety Equipment Equipment SECTION 7 − MAINTENANCE & TROUBLESHOOTING Apply Conductive Grease To Drive Roll Screw (See Sections 7-2 And 7-6) Conductive Replace Damaged Or Unreadable...

  • Page 37: Feeder Drive Assembly Maintenance

    7-1. Feeder Drive Assembly Maintenance Tools Needed: 5/16 in Retract wire onto spool. Pressure Roll Assembly Drive Motor Shaft Drive Roll Screw Use wire brush to clean drive roll. Drive Roll Idler Shoulder Washers Use wire brush to clean idler. Outlet Guide Wire Inlet Guide Pull guide toward rear of feeder to...

  • Page 38: Gun Drive Assembly Maintenance For An Xr-Edge Gun

    7-2. Gun Drive Assembly Maintenance For An XR-Edge Gun Tools Needed: 5/16 in OM-1594 Page 32 Conductive Grease Retract wire onto spool. Screw Drive Roll Use wire brush to clean drive roll. Install drive roll with hex opening down toward shaft hex, and secure with screw.

  • Page 39: Replacing Head Tube Liner In Xr-Edge Guns

    7-3. Replacing Head Tube Liner In XR-Edge Guns Turn OFF coolant supply before removing head tube water-cooled gun. The standard head tube liner will ac- commodate wire diameters from .030-1/16 wire size. When changing wire size, change control box drive roll and idler (see Section 7-1), gun pressure roll and drive roll (see Sections 7-2 and 7-6).

  • Page 40: Replacing The Liner

    7-4. Replacing The Liner Pistol Grip Gun Split End OM-1594 Page 34 XR-Edge Gun Ref. 151 599-F / Ref. 801 556-C / 801 564−E / Ref. 151 666-G / Ref. 200 371 Y Turn Off welding power source and wire feeder. Drive Roll Collet Nut Lay gun cable out straight.

  • Page 41: Changing Gun Contact Tip

    7-5. Changing Gun Contact Tip 7-6. Replacing Or Cleaning Gun Drive Roll In Pistol-Grip Guns Tools Needed: 5/64 in Remove nozzle Nozzle FasTip Unscrew FasTip. Install new FasTip. Ref. 150 437-A Turn Off wire feeder and welding power source. Top Cover Pressure Roll Assembly Cut off wire where it enters pressure roll assembly area.

  • Page 42: Replacing Or Cleaning Gun Drive Roll Bearing In Pistol-Grip Guns

    7-7. Replacing Or Cleaning Gun Drive Roll Bearing In Pistol-Grip Guns Tools Needed: 7-8. Replacing Head Tube Liner In Pistol-Grip Guns Tool Needed: 5/32 in OM-1594 Page 36 Turn Off wire feeder and welding power source. Top Cover Pressure Roll Assembly Screw Pressure Roll Remove as shown.

  • Page 43: Removing Diffuser In Air And Water-Cooled Pistol-Grip Guns

    7-9. 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 44: Replacing Hub Assembly

    7-10. Replacing Hub Assembly Tools Needed: 7/16 in OM-1594 Page 38 Remove gun top cover and release pressure arm (see Sections 5-9 and 5-10). Retract wire onto spool and remove spool. Take hub apart as shown. Metal Brake Washer Flat Washer Brake Washer Keyed Washer Spring...

  • Page 45: Overload Protection

    7-11. Overload Protection 7-12. 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 7-13 for remedies to this trouble. Y Turn Off wire feeder and welding power source.

  • Page 46: Troubleshooting

    7-13. Troubleshooting Trouble Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 5-3 or 5-5 as appli- Pressing gun trigger does not energize feeder. Welding wire is not energized. cable). Shielding gas does not flow Shielding gas does not flow.
  • Page 47 Notes OM-1594 Page 41...

  • Page 48: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram For Wire Feeder OM-1594 Page 42...
  • Page 49 218 814-B OM-1594 Page 43...
  • Page 50 218 815-A Figure 8-2. Circuit Diagram For XR Edge Gun 198 344-A Figure 8-3. Circuit Diagram For XR Pistol Grip Gun OM-1594 Page 44...
  • Page 51 Notes OM-1594 Page 45...

  • Page 52: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 802 230-C Figure 9-1. Main Assembly OM-1594 Page 46...
  • Page 53 Item Diagram Part marking ....089 572 ....112 167 ....134 327 .
  • Page 54 Item Diagram Part marking ... . . 028 770 ....073 562 ....134 201 .
  • Page 55 Item Diagram Part marking ....193 186 ....124 778 .
  • Page 56 Hardware is common and not available unless listed. Figure 9-3. Panel, Front w/Components (Water-Cooled Model Illustrated) OM-1594 Page 50 See Figure 9-1 Item 45 802 236-A...
  • Page 57 Item Diagram Part marking ....111 569 ....111 633 .
  • Page 58 Hardware is common and not available unless listed. Ref. 802 328-H Figure 9-4. Exploded View Of XR-Edge Gun OM-1594 Page 52...
  • Page 59 Item Part ... . . 187 000 Cover,Handle ... . . 187 002 Handle, Right ... . . 194 114 Kit, Drive Roll .030 (Part Of Wire Guide Kit 195 208) .
  • Page 60 Item Part ... . . 135 773 Knob, Adjust Tension Thumb ... . . 191 087 Ring, Rtng Ext .094 Shaft X .015 Thk E Style .
  • Page 61 Hardware is common and not available unless listed. Water Gun Barrel Figure 9-5. Barrel Assembly Of XR-Edge Gun Item Part Figure 9-5. Barrel Assembly Of XR-Edge Gun (Figure 9-4 Item 43) ... . . 199 613 Nozzle, Brass 5/8 In Orifice Tapered .
  • Page 62 Hardware is common and not available unless listed. Ref. 143 117-N Figure 9-6. Exploded View Of Pistol-Grip Gun OM-1594 Page 56...
  • Page 63 Item Diagram Part marking ... . . 214 745 Cover ... . . Deleted ..............
  • Page 64 Item Diagram Part marking ... . 166 412 Hose, Water 14in ... . 202 513 Fitting, Hose Brs Barbed M 3/16 Tbg X .250-20 (Air) .
  • Page 65 Hardware is common and not available unless listed. Figure 9-7. Barrel Assembly Of Pistol-Grip Gun Item Part Figure 9-7. Barrel Assembly Of Pistol-Grip Gun (Figure 9-6 Item 15) ... . . 199 613 Nozzle, Brass 5/8 In Orifice Tapered .

  • Page 66: Section 10 − Parts List Including Consumables

    SECTION 10 − PARTS LIST INCLUDING CONSUMABLES Item Number OM-1594 Page 60 Figure 10-1. Consumables Flowchart XR-A Spoolmatic Head Tube 6.0” STRAIGHT (#221 087) XR-W Head Tube 6.0” STRAIGHT (#221 519) XR-A Edge Head Tube 6.0” CURVE (#221 514) XR-W Edge Head Tube 6.0”...
  • Page 67 Item Part 10-1. 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 68 Item Part 10-1. Consumables Flowchart (Continued) Table 10-4. Tapered FasTipt Contact Tips* ... . 209024 .023 in (0.6 mm) ... . 209025 .030 in (0.8 mm) .
  • Page 69 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org...
  • Page 70 Notes...
  • Page 71 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after for your local the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 72: Owner's Record

    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. 2005 Miller Electric Mfg. Co. 1/05 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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