Miller XR-AlumaFeed Suitcase Owner's Manual
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Miller XR-AlumaFeed Suitcase Owner's Manual

Ce and non-ce models
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OM-285785G
2021−11
Processes
MIG (GMAW) Welding
Description
Wire Feeder And Feeder Gun
XR - AlumaFeed
™
®
Suitcase
CE And Non-CE Models
For product information,
File: MIG (GMAW)
Owner's Manual translations,
and more, visit
www.MillerWelds.com

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  • Page 1 OM-285785G 2021−11 Processes MIG (GMAW) Welding Description Wire Feeder And Feeder Gun XR - AlumaFeed ™ ® Suitcase CE And Non-CE Models 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 TABLE OF CONTENTS SECTION 7 − PROGRAMMING ............. . . 7-1.
  • Page 5 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. LLC, 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), Commission Regulation(s) and Standard(s).
  • Page 6 DECLARATION OF CONFORMITY for United Kingdom (UKCA marked) products. MILLER Electric Mfg. LLC, 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 Regulation(s) and Standard(s).

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 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 8 D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

  • Page 9: Additional Hazards For Installation, Operation, And Maintenance

    D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 10: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_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 et au mode opératoire. 2-1.
  • Page 12 D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...

  • Page 14: Proposition Californienne 65 Avertissements

    D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.

  • Page 15: 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 16 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Safe63 2012−06 Do not weld on drums or any closed containers. Safe16 2017−04 Do not remove or paint over (cover) the label. Safe20 2017−04 Drive rolls can injure fingers.

  • Page 17: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Amperes MIG-Start 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 Alternating Cur- Burnback Time rent Circuit Breaker...

  • Page 18: Section 4 − Specifications

    4-3. Information About Default Weld Parameters And Settings NOTICE − Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...
  • Page 19 D. 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 20: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Selecting a Location Do not move or operate unit where it could tip. Movement Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 21: Xr-Alumafeed Setup

    5-2. XR-AlumaFeed Setup Drive Roll Install proper drive rolls for wire size being used. Wire size is stamped on the face of roll. 14 Pin Control Cord Connect the 14−pin control cord to the welding power source being used. Gas Fitting Connect the 10ft.

  • Page 22: Xr-Pistol Grip Gun Setup

    5-4. XR-Pistol Grip Gun Setup Install contact tip for the wire being used. Install proper drive roll for the wire size being used. Refer to the consumable chart for dedicated drive roll size infor- mation. Line up drive roll groove with bearing groove and liner opening.

  • Page 23: Connections With A Constant Voltage (Cv) Or Constant Current/Constant Voltage (Cc/Cv) Welding Power Source Having A 14-Socket Receptacle

    5-6. Connections With A Constant Voltage (CV) Or Constant Current/Constant Voltage (CC/CV) Welding Power Source Having A 14-Socket Receptacle Ref.287262 24 VAC/Contactor Control 14-Pin Positive (+) Weld Cable Turn Off wire feeder and welding Plug power source. Stop engine on weld- Gas Hose ing generator.

  • Page 24: Air-Cooled Feeder Connections

    5-7. Air-Cooled Feeder Connections Turn power before connecting to weld terminal or receptacle. Failure to properly connect weld cables may cause excessive heat and start a fire, damage your machine. Gas Fitting Connect one end of 10 ft (3 m) gas hose to rear of unit, gas solenoid fit- ting.

  • Page 25: Air-Cooled Gun Connections

    5-8. Air-Cooled Gun Connections Ref.287262 / 287261 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. Tighten tighten threaded collar.

  • Page 26: 14-Pin Plug Information

    5-9. 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 27: Threading Welding Wire Through Feeder

    5-11. 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 28: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Controls START CRATER SCHD B SETUP ADVTRIG SETUP START CRATER Ref. 287265 Start Menu Indicator Start On Indicator 15 Setup Menu Indicator Crater Menu Indicator Start Button 16 Lower Display Volts Indicator 10 Setup Indicator 17 Wire Speed Indicator Schedule B Indicator 11 Setup Button...

  • Page 29: Controls (Continued)

    6-2. Controls (Continued) Setup Button Press and release the setup button allows Preflow, Post flow, Trigger Type and Run−in Control. Start Button Press the start button to turn the start se- quence on/off or press and hold to change the start variables. Start On Indicator Indicator is lit when the start is active.

  • Page 30: Mig Operation

    6-3. MIG Operation The voltage is adjusted using the Left Adjust knob. The wire speed is adjusted using the potentiometer in the gun handle. 6-4. Non-Synergic Pulsed MIG Operation The Arc Length setting is adjusted using the Left Adjust knob. The wire speed is adjusted using the poten- tiometer in the gun.

  • Page 31: Operational Terms

    6-6. 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 32: Jog/Purge

    6-7. 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 33: Section 7 − Programming

    SECTION 7 − PROGRAMMING 7-1. Setup Menu To enter the SETUP MENU press and re- for each weld process must be set at when the trigger control is set to (TRIG the power source. lease the SETUP button. The SETUP SPOT).

  • Page 34: Setup Menu Level 2

    7-2. Setup Menu Level 2 To enter the SETUP MENU LEVEL 2 press Voltage Range Limit (MIN) − Indicated in not welding. When set to (OFF), trigger and hold the SETUP button. The SETUP the LEFT DISPLAY with the VOLTS schedule select is disabled.

  • Page 35: Setting A Start Sequence In Synergic Pulse

    7-3. Setting A Start Sequence In Synergic Pulse To turn on a Start sequence, press the To exit the START MENU, press and re- Example: If the weld arc length is set to 50 START button. START lease the START button. and ARC.L is X0.50, the Start Arc Length is INDICATOR will illuminate indicating Start Items that can be adjusted in this menu are:...

  • Page 36: Setting A Start Sequence In Non−Synergic Pulse Or Mig

    7-4. Setting A Start Sequence In Non−Synergic Pulse Or MIG To turn on a Start sequence, press the Knob to change menu item values shown When MIG is selected in Setup Menu START button. START in the RIGHT DISPLAY. Level 1 the start arc length setting will INDICATOR will illuminate indicating Start be replaced by Start Voltage (VOLT).

  • Page 37: Setting A Crater Fill Sequence In Synergic Pulse

    7-5. Setting A Crater Fill Sequence In Synergic Pulse To turn on Crater Fill, press the CRATER lease the CRATER button. When the PULS 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 38: Setting A Crater Fill Sequence In Non−Synergic Pulse Or Mig

    7-6. Setting A Crater Fill Sequence In Non−Synergic Pulse Or MIG To turn on Crater Fill, press the CRATER To exit the CRATER MENU press and re- ting is dependent on the power source or button. The CRATER ON INDICATOR will lease the CRATER button.

  • Page 39: Profile Pulse

    7-7. 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 wire Profile Pulse Items that can be adjusted in consistently spaced ripple patterns, similar feed speed is 200 and (P.WFS) is set to the Setup Menu are:...

  • Page 40: Section 8 − Maintenance & Troubleshooting

    SECTION 8 − MAINTENANCE & TROUBLESHOOTING Disconnect power Maintain more often 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 41: 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. Bolt Flat Washer Spring Locking Washer Hub Nut Locking Washer Fiber Brake Washer Brake Strip 10 Bushing Replace broken or worn parts and slide parts onto shaft as shown.

  • Page 42: Troubleshooting

    8-4. Troubleshooting Disconnect power before troubleshooting. Trouble Remedy Pressing gun trigger does not energize Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 5-8). 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 43 Notes OM-285785 Page 37...

  • Page 44: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Wire Feeder OM-285785 Page 38...
  • Page 45 285819-B OM-285785 Page 39...
  • Page 46 Notes...
  • Page 47 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 48 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...

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