Miller XR-S Control Owner's Manual
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Miller XR-S Control Owner's Manual

Wire feeder and feeder gun
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OM-245777P
2016−06
Processes
MIG (GMAW) Welding
Description
Wire Feeder And Feeder Gun
XR - S Control
CE
For product information,
File: MIG (GMAW)
Owner's Manual translations,
and more, visit
www.MillerWelds.com

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  • Page 1 OM-245777P 2016−06 Processes MIG (GMAW) Welding Description Wire Feeder And Feeder Gun XR - S Control  For product information, File: MIG (GMAW) Owner’s Manual translations, and more, visit 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.

  • Page 4: Declaration Of Conformity

    DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

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

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir D Ne pas toucher à...

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

    déroule du soudage à l’arc, du soudage par points, du gougeage, D Placer les bouteilles debout en les fixant dans un support station- de la découpe plasma ou une opération de chauffage par naire ou dans un porte-bouteilles pour les empêcher de tomber ou induction.

  • Page 12: Proposition Californienne 65 Avertissements

    D N’utiliser que les pièces de rechange recommandées par le LE SOUDAGE À L’ARC risque de constructeur. provoquer des interférences. D Effectuer l’installation, l’entretien et toute intervention selon les manuels d’utilisateurs, les normes nationales, provinciales et de D L’énergie électromagnétique risque l’industrie, ainsi que les codes municipaux.

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.
  • Page 14 Do not weld on drums or any closed containers. Safe64 2012−06 Do not remove or paint over (cover) the label. Safe20 2012−05 Drive rolls can injure fingers. Safe32 2012−05 Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away. Safe33 2012−05 Environmental Protection Use Period (China) Safe123 2016−06...

  • Page 15: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Amperes Line Connection Increase Degree Of Continuous Protection Spot Weld Time Spot Welding MIG-Crater Primary Voltage Press To Set Duty Cycle Rated Current Purge Wire Feed Fuse Burnback Time MIG-Start Alternating Cur-...

  • Page 16: Section 4 − Spcifications

    SECTION 4 − SPCIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2.
  • Page 17 C. China EEP Hazardous Substance Information   ‡ China EEP Hazardous Substance Information Ö Hazardous Substance Component Name × (if applicable) PBDE Ö Brass and Copper Parts Coupling Devices Switching Devices Ö Cable and Cable Accessories Batteries SJ/T 11364 This table is prepared in accordance with China SJ/T 11364.

  • Page 18: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Connections With A Constant Voltage (CV) Or Constant Current/Constant Voltage (CC/CV) Welding Power Source Having A 14-Socket Receptacle Ref. 242 438-A / 245 947-A / 151 666-G 24 VAC/Contactor Control 14-Pin Positive (+) Weld Cable Turn Off wire feeder and welding Plug power source.

  • Page 19: 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 20: Air-Cooled Gun Connections

    5-3. Air-Cooled Gun Connections Left Side Ref. 246 218-A / 245 945-A / 242 435-A / 151 666-G 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 21: Water-Cooled Feeder Connections

    Coolant No. 043 809**; Distilled Or Deionized Water OK   Above 32 F (0 Coolant *HF: High Frequency Current **MILLER coolants protect to -37  F (-38  C) and resist algae growth. Tools Needed: 9/16 in. Ref. 246 218-C...

  • Page 22: 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 23: 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. Not used. Not used. Not used. Voltage feedback; 0 to +10 volts DC, 1 volt per 10 arc volts. Current feedback;...

  • Page 24: Threading Welding Wire Through Feeder

    5-8. Threading Welding Wire Through Feeder 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 25: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Front Panel Controls Wire Speed Display Displays preset wire speed in inches per minute. The gun wire speed control adjusts wire speed from minimum to maximum setting. The wire speed display is for reference only and cannot be calibrated.

  • Page 26: Jog/Purge

    6-2. 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: Setting Switches For Preflow And Postflow

    6-4. Setting Switches For Preflow And Postflow To set switches for preflow and postflow, pro- ceed as follows: Motor Control Board PC1 DIP Switch SW2 Preflow and postflow have preset time val- ues and cannot be changed. To change the factory default preflow and postflow settings, use a small nonconductive screwdriver to set switch SW2 in the posi- tions shown in the following tables.

  • Page 28: Section 7 − Maintenance & Troubleshooting

    SECTION 7 − 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 29: Replacing Hub Assembly

    7-2. 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 Fiber Washer Brake Washer Keyed Washer Spring Flat Washer Cap Screw Retaining Ring Replace broken or worn parts and slide parts onto shaft as shown.

  • Page 30: Troubleshooting

    7-4. 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 31 Notes OM-245777 Page 27...

  • Page 32: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram For Wire Feeder OM-245777 Page 28...
  • Page 33 245 790-C OM-245777 Page 29...

  • Page 34: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. Ref. 245 949-C Figure 9-1. Main Assembly OM-245777 Page 30...
  • Page 35 Item Diagram Part marking Description Quantity Figure 9-1. Main Assembly ....089572 Catch, Link-lock ..........
  • Page 36 Item Diagram Part Description marking Quantity Figure 9-1. Main Assembly (Continued) ....254843 Nut, Pg21 1.50 Hex X .375H Aluminum ......
  • Page 37 Item Diagram Part Description marking Quantity Figure 9-2. Motor & Wire Drive (Figure 9-1 Item 54) ....245931 Drive Assembly, Wire (Includes) ........
  • Page 38 Hardware is common and not available unless listed. 245 950-A Figure 9-3. Front Panel Assembly Item Diagram Part Description marking Quantity Figure 9-3. Front Panel Assembly (Figure 9-1 Item 53) ....... . Nameplate, (Order By Model And Serial Number) .
  • Page 39 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 40 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 2016 Miller Electric Mfg. Co. 2016−01...

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