Miller XR A Owner's Manual

Wire feeder and gun

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Miller

OWNER'S

IMPORTANT:

Read and understand

the power source manual used with this unit, with special emphasis on the safety

material throughout the manual, before installing, operating, or maintaining this

equipment. This unit and these instructions are for use only bypersons trained and

experienced in the safe operation of welding equipment. Do not allow untrained

persons to install, operate, or maintain this unit. Contact your distributor if you do

not fully understand these instructions.

cover2 8/91 - Ref. ST.151 666/ ST-145 432.A

February

Effective

MODEL:

MANUAL

the entire contents

of both this manual

1992

FORM:

OM-1581A

With

Serial

No. KCI 88391

XRATM

And XR wru

Wire

Feeder

And

Gun

and

MILLER ELECTRIC Mfg. co.

A Mirer Group Ltd., Company

P.O. Box 1079

Appleton, WI 54912 USA

Tel. 414-734-9821

PRINTED IN USA

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Summary of Contents for Miller XR A

Page 1 MILLER ELECTRIC Mfg. co. material throughout the manual, before installing, operating, or maintaining this A Mirer Group Ltd., Company equipment.
Page 2 AUGUST 6, 1990 Thiswarrantysupersedes all previousMILLERwarrantiesandis exclusivewith nootherguaranteesorwarrantiesexpressedor implied. In the case of MILLER's breach of warranty or any other duty LIMITED WARRANTY —Subject to the terms and conditions with respect to the quality of any goods, the exclusive remedies hereof, MILLER Electric Mfg.
Page 3 ERRATA SHEET FORM: OM-1581A June 3, 1992 Use above FORM number when ordering extra manuals. After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in this manual. CAUTION INCORRECT COOLANT OR COOLANT CONTAINING STOP-LEAK ADDITIVES can corrode and/or plug gun/ feeder cooling passages.
Page 4 RC2-3> RC2- > OM-1581A Page 2...
Page 5 0338 (ON-L ON-es (f-S07d)VEE (ON-ges)veq C-301'dS 88008 oono äää OM.1581A Page 3...
Page 7 WELDING SAFETY PRECAUTIONS WELDING be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. In welding. as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information that will be found in the Safety Standards listed on the next page.
Page 8 Keep cylinders away from any welding or other electrical CYLINDERS can explode if damaged. circuits. _ Shielding -gas cylinders contain gas under high Never allow a welding electrode to touch any cylinder. pressure. If damaged. a cylinder can explode. Since Use only correct shielding gas cylinders.
Page 9 TABLE OF CONTENTS SECTION 1 - SAFETY SIGNAL WORDS SECTION 2 - SPECIFICATIONS Duty Cycle 2-1. SECTION 3 - INSTALLATION Equipment Connection Diagrams . 3-1. Removing Top Cover Of Gun 3-2. Gun To Feeder Connections 3-3. Internal Connections To Feeder 3-4.
Page 11 SECTION 1 - SAFETY SIGNAL WORDS modi.l g,'91 The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instructions. WARNING statements identify procedures or practices which must be followed to avoid serious personal injury or loss of life.
Page 12 Duty cycle is how long the gun can operate within a ten minute period without causing overheating or damage. Both models are rated using argon or argon mixture shielding gas. The air-cooled model is rated at 100% duty cycle when operated at 200 amperes, allowing continuous welding. When operated at 250 amperes, the air-cooled model is rated at 60% duty cycle, allowing welding 6 minutes out of every 10 minutes.
Page 13 CV Or CC/CV Welding Power Source 115 VAC/Contactor Control 14-Pin Plug PLG5 Positive (+) Weld Cable Negative (—)Weld Cable Workpiece Voltage Sensing Lead Connect lead to workpiece for CC welding only. Wire Feeder 10 ft. (3 m) Gas Hose 115 VAC/Contactor Control Cord Gas Cylinder...
Page 14 CC Welding Power Source 5-Pin Or Twistlock Plug (Supplied) Positive (+) Weld Cable Negative Weld Cable Workpiece Voltage Sensing Lead Wire Feeder 10 ft. (3 m) Gas Hose 2-Conductor Contactor Con- trol Cord a-conductor 115 VAC Cord Gas Cylinder 115 VAC Plug Obtain plug for wire feeder.
Page 15 Removing Top Cover Of Gun 3-2. Top Cover Push back and lift off as shown. To reinstall cover, set rear of cover in gun, and push cover back and down until it clicks into position. Ret. ST.150 882.A Figure 3-5. Removing Top Cover Of Gun Gun To Feeder Connections 3-3.
Page 16 Water-Cooled Connections Gas Hose Connect to GAS fitting on feeder. Water Hose Connect to WATERTO GUN fitting on feeder (left-hand threads). Wire Conduit Thumbscrew Wire Conduit Block Loosen thumbscrew, insert conduit through WIRE opening un- tjJit bottoms against block. Tighten thumbscrew.
Page 17 Air-Cooled Feeder Connections Gas Hose Grommet Rear Panel 10 ft. (3 m) Gas Hose Rear Of Gas Fitting Route one end of gas hose through grommet, and connect hose to rear of GAS fitting in feeder. Connect re- maining end of hose to regulator/ flowmeter.
Page 18 Water-Cooled Feeder Connections Obtain coolant supply. Rear Panel Hose Grommet 10 ft. (3 m) Gas Hose Rear Of Gas Fitting Route one end of gas hose through grommet. and connect hose to rear of GAS fitting in feeder. Connect re- maining end of hose to regulator/ flowmeter.
Page 19 Adjusting Contact Tube Position 3-5. WARNING ELECTRIC SHOCK kill. • Do not touch live electncal parts. • Turn OFF wire feeder andwelding power source, and disconnect input power before inspecting or installing. Stop engine on welding generator. wfwaml.1 9/91 Contact Tube Nozzle Adjusting barrel changes contact tube...
Page 20 115 VAC/Contactor Control Plug Information 3-7. Interconnecting Cord 115 VAC/Contactor Control Plug PLG5 welding power source equipped with matching 14-socket receptacle, insert plug, and tighten threaded collar. Proceed to Section 3-9. If plug PLG5 will not connect to welding power source receptacle, use the following pin information and Section 3-8 to replace PLG5 with a suitable plug.
Page 21 Interconnecting Cord 115 VACIContactor Control Plug PLG5 Cut off plug. 5-Pin Plug Twistlock Plug 2-Conductor Cord connections shown in either Figure 3-3 or Figure 3-4, install 5-pin or twistlock plug as required, onto 2-conductor cord. For Figure 3-2 connection. obtain proper plug for connecting to con- tactor control receptacle on weld- ing power source.
Page 22 Threading Welding Wire 3-10. WARNING CYLINDERS can explode if damaged. ELECTRIC SHOCK can kill. • Keep cylinders away from welding and other • Do not touch live electrical parts. electrical circuits. The welding wire, drive rolls, drive assembly, and alf •...
Page 23 Feeding Welding Wire Through Gun Pressure Roll Assembly Lift arm and open pressure roll as- sembly. Wire Conduit Lay wire conduit out straight. Jog Switch Push JOG switch up to feed wire through wire conduit. Drive Roll Contact Tube Manually thread wire along drive roll groove and out contact tube 2 in.
Page 24 If operating at temperatures below freezing, use an ethylene glycol solution (Miller Part No. 128 705) in the cool- ant system. Do not use automotive-type antifreezes that contain anti-leak compounds which could block gun cooling passages. Do not change coolant unless it is discolored or dirty. Add soft, high-quality tap water, deionized water, or distilled...
Page 25 Insulating Gloves Safety Glasses With Side Shields Welding Helmet Wear dry insulating gloves, safety glasses with side shields. and a welding helmet with a correct shade of filter (see ANSI Z49.1). Sba.1 10/91 Figure 4-2. Safety Equipment Work Clamp use wire brush or sandpaper to clean metaf at weld joint area.
Page 26 VoltageN'/ire Speed Meter Voltage/Wire Speed Switch When switch is in VOLTAGE posi- VOLTAG/WIRE SPEED tion, and operator is welding, meter METER (OPTIONAL) displays arc voltage. Cable resis- tance and poor connections may cause displayed voltage to vary slightly from actual voltage at weld- ing arc.
Page 27 Voltage Control Use control to adjust arc voltage at the wire feeder. scale around control marked in percent. VOLTAGE Figure 4-8. Remote Voltage Control (Optional) Power Switch Use switch to turn unit ON and OFF. POWER Figure 4-9. Power Switch CAUTION Wire feeding system is designed for maximum of 50 psi (345 kPa) gas pressure.
Page 28 Open left side door. Fuse See Section 5-10. Circuit Breaker CBI See Section 5-10. Motor Torque Switch Use switch to select the force used to push wire. The up position is for low force, or torque. The down po- sition is for high force, or torque. If welding wire appears to be...
Page 29 Coolant Supply Turn on coolant supply before welding. Turn off coolant supply when fin- ished welding. Ret. ST.150 7554 Figure 4-14. Coolant Supply For Water-Cooled Models Only Readjust Controls And Prepare For Production Figure 4-15. Sequence Of Gas Metal Arc Welding (GMAW)- Continuous Or Spot SECTION 5 - MAINTENANCE &...
Page 30 Changing Or Cleaning Gun Drive Roll 5-2. ELECTRIC SHOCK, MOVING PARTS,AND HOT PARTS HAZARDS. Read safety infor- WARNING mation at beginning of Section 5 before proceeding. Turn OFF wire feeder and welding power source. Top Cover Pressure Roll Assembly Cut off wire where it enters pres- sure roll assembly area.
Page 31 Changing Feeder Drive Roll And Wire Inlet Guide 5-3. ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read safety infor- WARNING mation at beginning of Section 5 before proceeding. Turn OFF wire feeder and welding power source. Lay wire conduit out straight.
Page 32 Replacing Or Cleaning Gun Drive Roll Bearing 5-4. ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read safety infor- WARNING mation at beginning of Section 5 before proceeding. Turn OFF wire feeder and welding power source. Top Cover Pressure Roll Assembly Screw Shoulder Washer...
Page 33 Changing Gun Contact Tube And Liner 5-6. ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read safety infor- WARNING mation at beginning of Section 5 before proceeding. Turn OFF wire feeder and welding power source. Remove top cover and open pres- sure roli assembly as shown in Figure 5-3.
Page 34 Water-Cooled Models 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. Wipe gun dry before putting it back together.
Page 35 Adjusting Hub Tension 5-9. WARNING ELECTRIC SHOCK can kill. • Do not touch live electrical parts. The welding wire, drive rolls, drive assembly,and all metal partstouching the welding wire are electrically livewhen welding power source is energized. This procedure requiresan energized welding power sourceand wire feeder. Only quafified persons are to make this adjustment. Turn ON welding power source and wire feeder to make this adjust.
Page 36 5-11. Water Flow Switch (Optional For Water-cooled Models) The water flow switch protects the gun from overheating. If coolant flowrate drops below 1 qt./min., the water flow switch opens and stops the welding wire from feeding. See Table 5-2 for remedies to this trouble. 5-12.
Page 37 Section Remedy Trouble 5-10 Reset circuit breaker CBI . Pressing gun trigger wili not feed wire, wire is not ener- gized. shielding gas flows, and switch activates motor. Be sure weld cable is routed through current sensing relay. Feeder feeds wire but remains in run-in...
Page 38 SECTION 6 - ELECTRICAL DIAGRAMS RC2-3> — — < NC 15-7 PC2-l > < RClO-3 8>1220 0M-1581 Page 28...
Page 39 8008...
Page 40 puLL ASSEMBLY MOTOR TRIGGER PLG2 CORD CORD SA-t38 956-A Figure 6-3. Circuit Diagram For Gun SIDE VIEW BLK-MTR(BLK-CROI RED-MTR(RED-CRDI I (WHT-CRD2) Rd-2-CRD2) R4-J(RED-CRD2) PBI -3tBRN-CRD2) HOUSING BLR-tRDl (BLk-urm RED-CROI (RED-MT) HOUSING (BPN-CPDt -CROI aRN-CRC1 (HOUSING) BOTTOM -CR02 VIEW WHT-CR02(Rd- CRD2 RED-CR02(R4-3) BLOCR02(Ra-2) PB I -a (WHT -CROI)
Page 41 NOTES OM-1581 Page 31...
Page 42 SECTION 7 - PARTS LIST OM.1581 Page 32...
Page 43 Dia. part Item Quantity Description Mkgs. Figure 7-1. Main Assembly CATCH, link-lock ... 089 572 INSULATOR, door . 112167 LABEL, warning general precautionary WRAPPER +113 CLAMP, saddle 126415 HANDLE, molded 126416 RING, retaining spool 058 427 WASHER, fiat sti .250 ID x .875 OD x .062thk 602 233 SPRING, cprsn .845 OD x .091 wire x 1.500 057 543...
Page 44 Item Dia. part Mkgs. Description Quantity Figure 7-1. Main Assembly (Continued) CAPACITOR 117 500 SNUBBER, polye MF .5uf 200VDC CLIP, mtg resistor .312 ID core RESISTOR, WW fxd 25W 200 ohm CAPACITOR, polye film 2.3uf 250VAC 114 215 45 • CAPACITOR, polye film .47uf 400VDC STRIP, term 3P...
Page 45 Dia. Item Part Quantity Mkgs. Description Figure 7-2. Motor & Wire Drive (Fig 7-1 Item 70) DRIVE ASSEMBLY, wire (consisting of) . 115 191 RING, retainer 058 968 WASHER, shldr nyl .375 OD x .168 ID x .080thk 605 798 SPRING, tension pressure roll .
Page 46 See Fig 7-1 Item 58 SD-145 127.A Figure 7-3. Panel, Front w/Components (XR-W Model Illustrated) OM-1581 Page 36...
Page 47 Item Dia. Part Quantity Mkgs. Description Figure 7-3. Panel, Front w/Components (Fig 7-1 Item 58) METER, flow 6-60 . ++111 GUARD, flow meter ++111 HOSE, SAE .187 ID x .410 OD (order byft) ++134 FITTING, hose brs barbed nipple 3/16tbg ..++056 FITTING, hose brs nut .625-18 ++010...
Page 48 OM-1581 Page 38...
Page 49 Item Dia. Part Quantity M kgs. Description Figure 7-4. Exploded View Of Gun COVER • 133 479 SPRING, closure cover CONDUIT w/FlTTlNG, 15ft (XR-15A & W models) 112 715 CONDUIT w/FlTTtNG, 30ft (XR-30A & W models) 112 716 HOSE, water in (XR-15W model) (consisting of) HOSE, water in (XR-30W model) (consisting of) HOSE, gas in (XR-15A &...
Page 50 Item Dia. Part Quantity Mkgs. Description Figure 7-4. Exploded View Of Gun (Continued) 262. CLAMP, head tube SCREW, cap sti sch 10-24 x 1 .OOO SPRING, cprsn .445 OD x .023 wire x .370 WASHER, flat felt .234 ID x .500 OD x .093thk 146 558 KIT, current pick-up contact SCREW, set sti sch 8-32 x .125 cup point (XR-15A &...
Page 51 Item Dia. part Mkgs. Description Quantity Figure 7-4. Exploded View Of Gun (Continued) NOZZLE, spot inside corner +000 EXTENSION, nozzle (XR-15A & 30A models) 144 862 EXTENSION, barrel 2.875 lg (XR-15A & 30A model) TUBE, contact .025/31 wire .135 TUBE, 030/36 wire contact...

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