Miller XR-Aluma-Pro 15W Owner's Manual
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Miller XR-Aluma-Pro 15W Owner's Manual

Air and water-cooled guns
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For product information,
Owner's Manual translations,
and more, visit
www.MillerWelds.com
XR-Aluma-Pro Plus
(Air And Water-Cooled Guns)
CE And Non-CE Models
300 Ampere (Air) Push-Pull Welding Gun
400 Ampere (Water) Push-Pull Welding Gun
OM-285555C
2021−05
Processes
MIG (GMAW) Welding
Description
Semi-Automatic, Air/Water-
Cooled, MIG (GMAW) Welding
Gun
™
File: MIG (GMAW)

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Summary of Contents for Miller XR-Aluma-Pro 15W

  • Page 1 OM-285555C 2021−05 Processes MIG (GMAW) Welding Description Semi-Automatic, Air/Water- Cooled, MIG (GMAW) Welding ™ XR-Aluma-Pro Plus (Air And Water-Cooled Guns) CE And Non-CE Models 300 Ampere (Air) Push-Pull Welding Gun 400 Ampere (Water) Push-Pull Welding Gun 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 FOR GMAW WELDING GUNS − READ BEFORE USING ..1-1. Symbol Usage ............... 1-2.
  • Page 4 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 For Gmaw Welding Guns − Read Before Using

    SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING SR7 (MIG) 2020-02 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: California Proposition 65 Warnings

    NOISE can damage hearing. READ INSTRUCTIONS. D Read and follow all labels and the Owner’s Noise from some processes or equipment can damage hearing. Manual carefully before installing, operating, or servicing unit. Read the safety information at D Check for noise level limits exceeding those the beginning of the manual and in each specified by OSHA.

  • Page 7: Utilisation

    SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT UTILISATION SR7(MIG)_2020−02_fre 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...

  • Page 8: Proposition Californienne 65 Avertissements

    D Avoir recours à des écrans protecteurs ou à des rideaux pour D Utiliser des bouche-oreilles ou des serre-tête antibruit approuvés si protéger les autres contre les rayonnements les éblouissements le niveau de bruit est élevé. et les étincelles ; prévenir toute personne sur les lieux de ne pas D Avertir les personnes à...

  • Page 9: 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 10: Section 4 − Introduction

    SECTION 4 − INTRODUCTION 4-1. Specifications Model Welding Output Range Electrode Wire Feed Net Weight Wire Diameter Speed Range (Torch Only) Capacity XR-A Aluma-Pro Plus 15 ft (4.7 m) 300 A at 100% Duty Cycle .030 To 1/16 in. 70 To 900 ipm 2.2 lb (1.0 kg) XR-A Aluma-Pro Plus 25 ft (7.6 m) (0.8 To 1.6 mm)

  • Page 11: Duty Cycle And Overheating

    4-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle can damage unit and void warranty. Air-Cooled Models 100% Duty Cycle At 300 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns Continuous Welding Water-Cooled Models (CE) 100% Duty Cycle At 400 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns...

  • Page 12: Section 5 − Installation

    SECTION 5 − INSTALLATION Be sure that contact tip, liner, and drive rolls are correct for wire size and type. See Parts List to change parts as needed. 5-1. Equipment Connection Diagram - Single Feeder Welding Power Source Contactor Control/Power Cord Positive (+) Weld Cable Negative (−) Weld Cable Workpiece...

  • Page 13: Equipment Connection Diagram - Dual Feeder

    5-2. Equipment Connection Diagram - Dual Feeder Welding Power Source Contactor Control/Power Cord Positive (+) Weld Cable Negative (−) Weld Cable Workpiece Welding Gun Wire Feeder Gas Hose Gas Cylinder and Regulator (Customer Supplied) Shielding gas pressure not to exceed 100 PSI (689 kPa). 10 Coolant Hoses - Water−...

  • Page 14: 14-Pin Plug Information For Connecting Wire Feeder To Power Source

    5-3. 14-Pin Plug Information For Connecting Wire Feeder To Power Source Pin* Pin Information Motor 0 to +24 volts DC with respect to pin 2 Motor Common +5 volts DC tachometer power Tachometer ref Tachometer signal Trigger Trigger Wire speed ref. +5 volts DC Wire speed com Wire speed 0 to +5 volts DC with respect to pin 9 Gun sensing resistor with respect to pin 9...

  • Page 15: Threading Welding Wire Through Gun

    5-5. Threading Welding Wire Through Gun Refer to wire feeder manual for instructions on feeding wire through feeder. For XR-Aluma-Pro Plus Gun: JOG / PURGE Welding wire is electrically live when gun trigger is used to jog wire. Turn OFF coolant supply before threading wire Lay gun cable out straight.

  • Page 16: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Gun Controls Trigger Press trigger to energize welding power source contactor applicable), start shielding gas flow, and begin wire feed. Controls at the wire feeder can be set to provide timed shielding gas preflow and postflow when trigger is pressed and released.

  • Page 17: Shielding Gas

    Maximum inlet pressure: 70 psi (483 kPa) Distilled Or Deionized Water OK Minimum cooling power: 6820 BTU/hr (2 kW) ° ° Above 32 F (0 Coolant ° ° *MILLER coolants protect to -37 F (-38 C) and resist algae growth. Ref. 150755-A OM-285555 Page 13...

  • Page 18: Gun Drive Assembly Maintenance For An Xr-Aluma-Pro Plus Gun

    6-5. Gun Drive Assembly Maintenance For An XR-Aluma-Pro Plus Gun Lever Arm Using lever arm open pressure roll with bearing as shown. Push for- ward to lock in place. Retract wire onto spool. Drive Roll Use wire brush to clean drive roll. Install drive roll with hex opening down toward shaft hex, and secure with screw.

  • Page 19: Replacing Head Tube Liner In Xr-Aluma-Pro Plus Guns

    6-6. Replacing Head Tube Liner In XR-Aluma-Pro Plus Guns Turn OFF coolant supply before removing head tube water-cooled gun. The standard head tube liner (yellow) will accommodate wire diameters from 3/64 in.- 1/16 in. wire size. When changing wire size, change control box drive roll, idler and head tube liner with appropriate sized liner.

  • Page 20: Replacing The Gun Liner On Xr-Aluma-Pro Plus Guns

    6-8. Replacing The Gun Liner On XR-Aluma-Pro Plus Guns Gun End Refer to instructions below. Remove Old Liner (Item 2) From Gun End Install New Liner (Item 2) Into Gun End Power Pin End Gently pry open slots to remove wire collet guide.

  • Page 21: Section 7 − Maintenance & Troubleshooting

    SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance For Aluminum Push/Pull Guns Disconnect power before maintaining. n = Check ~ = Clean l = Replace Daily n~ Head Tube Liner and Drive Casting (see Section 6-6) Weekly n~ Drive Roll Every Spool of Wire...

  • Page 22: Cleaning The Gun Liner On Xr-Aluma-Pro Plus Guns

    7-2. Cleaning The Gun Liner On XR-Aluma-Pro Plus Guns Turn Off welding power source and wire feeder. NOTICE − Clean gun liner be- fore cleaning stainless tube and inlet guide. Lay gun cable out straight. Cable Cover Jacket Remove cable cover jacket as described in Section 6-8 to ac- cess liner assembly.

  • Page 23: Troubleshooting Table

    7-3. Troubleshooting Table Disconnect power before troubleshooting. Trouble Remedy No wire feed at gun, feeder not operat- Reset circuit breaker at power source. See power source owner’s manual. ing. Check motor or brake solenoid. Replace trigger-switch and test operation. Check trigger-switch wires for continuity. Reset circuit breaker in feeder/control box and check for short in motor leads.

  • Page 24: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS M1676-C Figure 8-1. Circuit Diagram For XR-Aluma-Pro Plus Gun Notes OM-285555 Page 20...
  • Page 25 Notes OM-285555 Page 21...

  • Page 26: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. Figure 9-1. Exploded View Of XR-Aluma-Pro Plus Gun OM-285555 Page 22...
  • Page 27 Lock Unlock M1671 M1672 Ref. T0096-A Item Part Description Quantity Figure 9-1. Exploded View Of XR-Aluma-Pro Plus Gun ... . . 245981 Head Tube Assy, Water Cooled (Long) ........
  • Page 28 Item Part Description Quantity Figure 9-1. Exploded View Of XR-Aluma-Pro Plus Gun (Continued) ....M1658 Kit, Conduit Monocoil 15 Ft ..........
  • Page 29 Item Part Description Quantity Figure 9-1. Exploded View Of XR-Aluma-Pro Plus Gun (Continued) ... . ++M1672 Drive Assy, Replacement Water ........
  • Page 30 Hardware is common and not available unless listed. T0084-A Figure 9-3. (Air) Head Tube Assembly Of XR-Aluma-Pro Plus Gun Item Part Description Quantity Figure 9-3. (Air) Head Tube Assembly Of XR-Aluma-Pro Plus Gun (Figure 9-1 Item 2) ....245979 Head Tube Assy, Air (Long) (Includes) .

  • Page 31: Section 10 − Parts List Including Consumables

    SECTION 10 − PARTS LIST INCLUDING CONSUMABLES Item Number XR-Aluma-Pro Plus 6” Head Tube Insulators Centerfire Nozzles Air (Long) (245979) Nozzle Centerfire Centerfire Insulator Contact Tips Diffusers (232284) N − 3414C XR-Aluma-Pro Plus N − 5818C 6” Head Tube T − 035AL D −...
  • Page 32 Table 10-5. Head Tube Assemblies ... . . 245981 Head Tube Assy Water Cooled (Long) ........
  • Page 33 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 34 Notes...
  • Page 35 Effective January 1, 2021 (Equipment with a serial number preface of NB or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions TIG Torches (No Labor) below, Miller Electric Mfg.
  • Page 36 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 2021 Miller Electric Mfg. LLC 2021−01...

This manual is also suitable for:

Xr-aluma-pro 25wXr-aluma-pro 35wXr-w aluma-pro plus 15Xr-w aluma-pro plus 25301571301572 ... Show all

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