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Summary of Contents for Miller XR-ALUMAFEED
- Page 1 OM-239 210A 2009−01 Processes MIG (GMAW) Welding Description Wire Feeder And Feeder Gun XR - AlumaFeed ™ File: MIG (GMAW) Visit our website at www.MillerWelds.com...
- Page 2 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1. -
Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. - Page 6 D Do not use welder to thaw frozen pipes. FUMES AND GASES can be hazardous. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Welding produces fumes and gases. Breathing D Wear oil-free protective garments such as leather gloves, heavy these fumes and gases can be hazardous to your shirt, cuffless trousers, high shoes, and a cap.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards. 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. -
Page 8: California Proposition 65 Warnings
1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &... -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007−04 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques. - Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un in les sources de soudage onduleur quand on a cendie ou une explosion. coupé l’alimentation. Le soudage effectué sur des conteneurs fermés tel D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peu décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, ACCUMULATIONS des chocs mécaniques, des dommages physiques, du laitier, des risquent de provoquer des blessures flammes ouvertes, des étincelles et des arcs. ou même la mort. D Placer les bouteilles debout en les fixant dans un support station- D Fermer l’alimentation du gaz protecteur en cas naire ou dans un porte-bouteilles pour les empêcher de tomber ou de non-utilisation. -
Page 12: Proposition Californienne 65 Avertissements
LES FILS DE SOUDAGE peuvent LE RAYONNEMENT HAUTE FRÉ- provoquer des blessures. QUENCE (H.F.) risque de provoquer des interférences. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Le rayonnement haute fréquence (H.F.) peut D Ne pas diriger le pistolet vers soi, d’autres per- provoquer des interférences avec les équipe- sonnes ou toute pièce mécanique en enga- ments de radio−navigation et de communica-... -
Page 13: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.csa-international.org). Internet : www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, de American National Standards Institute, Recommended Safe Practices for the Preparation for Welding and Cut- 11 West 43rd Street, New York, NY 10036-8002 (téléphone :... - Page 14 OM-239 210 Page 10...
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Page 15: Section 3 − Definitions
SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions 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 − keep hands and metal objects clear. -
Page 16: Symbols And Definitions
Spool Brake/Drive Roll Pressure Label CE 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. See Section 5-8 for recommended tension settings. -
Page 17: Section 4 − Introduction
SECTION 4 − INTRODUCTION 4-1. Specifications Wire Type of Input Welding Power Wire Feed Welding Overall Diameter Weight Power Source Type Speed Range Circuit Rating Dimensions Range Constant Voltage (CV) Length: 21-1/4 in 0.035 To .062 in DC For GMAW Or (540 mm) 24 Volts AC (0.9 To 1.6 mm) -
Page 18: Air-Cooled Feeder Connections
5-2. Air-Cooled Feeder Connections Gas Fitting Connect one end of 10 ft (3 m) gas hose to rear of unit, gas solenoid fit- ting. Connect remaining end of hose to regulator/flowmeter. Shielding gas pressure not to exceed 100 psi (689 kPa). Weld Cable To Welding Power Source Select and prepare weld cable... -
Page 19: Air-Cooled Gun Connections
5-3. Air-Cooled Gun Connections Left Side Ref. 242 435-A / 805 352-A / 805 351-A Gun Control Cable Gun Bushing Loosen gun securing knob and insert gun power pin through gun bushing until it Insert plug into Gun Control receptacle, and Gun Securing Knob bottoms against drive casting. -
Page 20: Water-Cooled Feeder Connections
° ° Above 32 F (0 Tools Needed: Coolant 9/16 in *HF: High Frequency Current ° ° **MILLER coolants protect to -37 F (-38 C) and resist algae growth. Ref. 152 431-A / Ref. 805 350-A OM-239 210 Page 16... -
Page 21: Water-Cooled Gun Connections
5-5. Water-Cooled Gun Connections Turn on coolant supply before welding or gun will be dam- aged. Gun Control Cable Insert plug into Gun Control receptacle, and tighten threaded collar. Gun Power Pin Gun Securing Knob Gun Bushing Drive Casting Loosen gun securing knob, and insert gun power pin through gun bushing until it bottoms against drive casting. -
Page 22: 14-Pin Plug Information
5-6. 14-Pin Plug Information Pin* 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. +10 volts DC input from power source to wire feeder with respect to socket D. Remote control circuit common. -
Page 23: Threading Welding Wire Through Feeder
5-8. Threading Welding Wire Through Feeder Tools Needed: Hold wire tightly to keep it from unraveling. 6 in (150 mm) Pull and hold wire; cut off end. Tension Arm Open tension arm. Install proper size drive rolls. Thread wire thru inlet guide, along drive roll groove, and into wire conduit. -
Page 24: Section 6 − Operation
SECTION 6 − OPERATION 6-1. Controls SETUP START SCHD B CRATER ADVTRIG SETUP START CRATER JOG / PURGE WATER IN WATER OUT GUN CONTROL 805 354-A Start Button Crater Menu Indicator 15 Advanced Trigger Indicator Setup Button Start Menu Indicator 16 Wire Speed Indicator Setup Indicator 10 Left Display... -
Page 25: Operational Terms
6-2. Operational Terms The following is a list of terms and their definitions as they apply to the wire feeder: General Terms: CV weld process with individual settings of voltage and wire speed. Pulsed MIG CC weld process with factory taught data using peak and background current, pulse width and pulses per second. -
Page 26: Jog/Purge
6-3. Jog/Purge Pressing the Jog/Purge switch allows the activated, the feeder will perform a jog op- is set to for welding. operator to jog wire without energizing the eration for a maximum of 2 minutes. If the S Jogging can also be accomplished by weld power or gas valve circuit. -
Page 27: Section 7 − Programming
SECTION 7 − PROGRAMMING 7-1. Setup Menu To enter the SETUP MENU press and re- when the trigger control is set to (TRIG be allowed to be active. Range of this set- lease the SETUP button. The SETUP HOLD). Trigger hold delay time is the min- ting is from (0.0 to 5.0) seconds. -
Page 28: Setup Menu Level 2
7-2. Setup Menu Level 2 To enter the SETUP MENU LEVEL 2 press process. If the power source weld process VOLTS INDICATOR illuminated. When set and hold the SETUP button. The SETUP is set to PULSED MIG, the minimum to (ARC.L), the preset arc length will be MENU INDICATOR and the SETUP voltage range limit setting will change if the shown in the Left Display with the ARC... -
Page 29: Setting A Start Sequence
7-3. Setting A Start Sequence To turn on a Start sequence, press the lease the START button. and ARC.L is X0.50, the Start Arc Length is START button. START Items that can be adjusted in this menu are: INDICATOR will illuminate indicating Start When the DISP option in the SETUP is active. -
Page 30: Setting A Crater Fill Sequence
7-4. Setting A Crater Fill Sequence To turn on Crater Fill, press the CRATER lease the CRATER button. When the DISP option in the SETUP button. The CRATER ON INDICATOR will MENU LEVEL 2 is set to VOLT, the Items that can be adjusted in this menu are: illuminate indicating Crater Fill is active. -
Page 31: Profile Pulse
7-5. Profile Pulse Profile Pulse optimizes Aluminum weld set to (YES). See section 7-2. unit is set to for welding. Range of this set- bead appearance by producing welds with ting is (X0.00 to X0.30). Example: If the Profile Pulse Items that can be adjusted in consistently spaced ripple patterns, similar wirefeed speed is 200 and (P.WFS) is set to the Setup Menu are:... -
Page 32: Section 8 − Maintenance & Troubleshooting
SECTION 8 − MAINTENANCE & TROUBLESHOOTING Maintain more often Disconnect power before maintaining. during severe conditions. 3 Months Clean Replace Replace Damaged Damaged Or Tighten Gas Hose Unreadable Weld Labels Terminals Repair Or Replace Cracked Cables And Cords 6 Months Clean Blow Out Or Drive... -
Page 33: Replacing Hub Assembly
8-2. Replacing Hub Assembly Remove gun top cover and release pressure arm. Retract wire onto spool and remove spool. Take hub apart as shown. Metal Brake Washer Flat Washer Brake Washer Keyed Washer Spring Cap Screw Retaining Ring Replace broken or worn parts and slide parts onto shaft as shown. -
Page 34: Troubleshooting
8-4. Troubleshooting Disconnect power before troubleshooting. Trouble Remedy Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 5-3). Pressing gun trigger does not energize feeder. Shielding gas does not flow and Have nearest Factory Authorized Service Agent check optional water flow switch, if applicable. wire feeder does not feed. - Page 35 Notes OM-239 210 Page 31...
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Page 36: Section 9 − Electrical Diagrams
SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Wire Feeder OM-239 210 Page 32... - Page 37 239 209-B OM-239 210 Page 33...
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Page 38: Section 10 − Parts List
SECTION 10 − PARTS LIST Hardware is common and not available unless listed. 242 437-A Figure 10-1. Main Assembly OM-239 210 Page 34... - Page 39 Item Diagram Part marking Description Quantity Figure 10-1. Main Assembly ....089 572 Catch, Link-lock ..........
- Page 40 Item Diagram Part Description marking Quantity Figure 10-1. Main Assembly (Continued) ....214 860 Nut, Ln Pg21 1.26Hex .14H Nickel Plated Brass ..... .
- Page 41 Item Diagram Part Description marking Quantity Figure 10-2. Motor & Wire Drive (Figure 10-1 Item 54) ....239 208 Drive Assembly, Wire (Includes) ........
- Page 42 Hardware is common and not available unless listed. See Figure 10-1 Item 53 242 491-A Figure 10-3. Front Panel Assembly Item Diagram Part Description marking Quantity Figure 10-3. Front Panel Assembly (Figure 10-1 Item 53) ..... 213 134 .
- Page 43 Effective January 1, 2009 (Equipment with a serial number preface of LK or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions...
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Page 44: Options And Accessories
Contact the Delivering Carrier to: 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2009 Miller Electric Mfg. Co. 2009−01...
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