Instruction/ maintenance manual of the product XR A Miller Electric
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X R A A n d X R W Processes Description MIG (GMA W) W elding Wire Feeder And Feeder Gun OM-1581 137 532Y 2007 − 01 ™™ Visit our website at www.MillerWelds.
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 5 − OPERA TION 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Front Panel Controls Of Feeder (Air-Cooled Model Shown) 24 . . .
OM-1581 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
OM-1581 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
OM-1581 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.
OM-1581 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .
OM-1581 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
OM-1581 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
OM-1581 Page 7 2-3 . Dange rs suppléme ntaire s en r e lation avec l’installa tion, le f onctionne ment et l a maintena nce Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables.
OM-1581 Page 8 2-5. Princi pales no rmes de sécurit é Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .
OM-1581 Page 9 SECTION 3 − SPECIFICA TIONS 3-1. Wire Feeder Specifications Specification Description T ype Of Input Power 1 15 V olts AC, 3 Amperes At 50/60 Or 100 Hz Power Control Circuit V oltage Provided At Gun 30 V olts DC Wire Feed Speed Range 70-875 ipm (1.
OM-1581 Page 10 SECTION 4 − INST ALLA TION Be sure that contact tip, liner , and drive rolls are correct for wire size and type. See Section 5 to change parts as needed. See Section 7 for list of other available contact tips. NOTE Review Section 4 -1 through Section 4- 4 to determine how equipment will be connected.
OM-1581 Page 1 1 4-2. Connections With A CV Welding Power Source Having Separate 1 15 V AC And Contactor Control Receptacles 1 Constant Voltage (CV) W eld- ing Power Source 2 Plug Obtain matching plugs for connect- ing to power source receptacles. 3 W orkpiece 4 V oltage Sensing Lead Do not connect to workpiece.
OM-1581 Page 12 4-4. Connections With A CC W elding Power Source And A 1 15 V AC/12 VDC Secondary Contactor 1 Constant Current (CC) Weld - ing Power Source 2 W orkpiece 3 V oltage Sensing Lead 4 Gun 5.
OM-1581 Page 13 4-6. Air-Cooled Gun Connections 3 1 Gu n Control Cable Insert plug into Gun Control recep- tacle, and tighten threaded collar . 2 Gas Hose Connect to Gas fitting on feeder . 3 Weld Cable 4 Weld Cable T erminal In Feeder Connect gun weld cable to weld cable terminal in feeder .
OM-1581 Page 14 4-7. W ater-Cooled Gun Connections 1 Gas Hose Connect to Gas fitting on feeder . 2 Water Hose Connect to water to gun fitting on feeder (left-hand threads). 3 Wire Conduit 4 Thumbscrew 5 Wire Conduit Block Loosen thumbscrew , and insert conduit through Wire opening until it bottoms against block.
OM-1581 Page 15 4-8. Air-Cooled Feeder Connections 1 Gas Hose Grommet 2 10 ft (3 m) Gas Hose 3 Rear Of Gas Fitting Route one end of gas hose through grommet, and connect hose to rear of Gas fitting in feeder . Connect remaining end of hose to regulator/flowmeter .
OM-1581 Page 16 4-9. W ater-Cooled Feeder Connections Obtain coolant supply . 1 Gas Hose Grommet 2 10 ft (3 m) Gas Hose 3 Rear Of Gas Fitting Route one end of gas hose through grommet, and connect hose to rear of Gas fitting in feeder . Connect remaining end of hose to regulator/flowmeter .
OM-1581 Page 17 4-10. V oltage Sensing Lead Connections Unit is factory set for constant volt- age (CV) welding. T o set unit for constant current (CC) welding, proceed as follows: 1 T erminal Strip 2T 2 Strain Relief Loosen screws of strain relief.
OM-1581 Page 18 4-1 1. 1 15 V AC/Contactor Control Plug Information 1 Interconnecting Cord 2 1 15 V AC/Contactor Control Plug PLG5 If CC or CC/CV welding power source is equipped with matching 14-socket receptacle, insert plug, and tighten threaded collar .
OM-1581 Page 19 4-12. Replacing 1 15 V AC/Contactor Control Plug With Customer-Supplied 5-Pin Or T wistlock Plug 1 1 15 V AC/Contactor Control Plug PLG5 2 Contactor Control Cord 3 1 15 V AC Cord Find .
OM-1581 Page 20 4-13. Installing Wire Spool T urn Off wire feeder and welding power source. 1 Wire Spool 2 T op Cover 3 Pressure Roll Assembly 4 Gun Contact Tip If wire spool is being replaced, open pressure roll assembly in gun, and cut welding wire off at contact tip.
OM-1581 Page 21 4-14. Threading W elding Wire Through Feeder 1 Wire Spool Loosen wire from spool, cut off bent wire, and pull 6 in (150 mm) of wire of f spool. 2 T ension Arm 3 Mounting Arm T o open pressure roll assembly , open tension arm and lift mounting arm.
OM-1581 Page 22 4-15. Threading W elding Wire Through Gun 1 Pressure Roll Assembly Lift arm and open pressure roll assembly . 2 Wire Conduit Lay wire conduit out straight. 3 Jog Switch Push Jog switch up to feed wire through wire conduit. 4 Drive Roll Fo r wire sizes .
OM-1581 Page 23 4-17. Adjusting Wire Feed Starting Speed 1 2 T op Of PC1 Ref. 151 772-B / Ref. 142 054-B T o adjust wire feed starting speed, proceed as follows: T urn Of f wire feeder and welding power source.
OM-1581 Page 24 SECTION 5 − OPERA TION 5-1. Front Panel Controls Of Feeder (Air-Cooled Model Shown) 1 V oltage/Wire Speed Meter (Optional) 2 V oltage/Wire Speed Switch (Optional) 3 Run-In Speed Cont.
OM-1581 Page 25 5-4. Run-In Speed Control 1 Run-In Speed Control Use control to set wire feed speed before arc initiation. After arc initiation, wire feed speed is controlled by the Wire Speed Control on the welding gun (see Section 5-12 ). Th e scale around the control is per- cent of full range, not wire speed.
OM-1581 Page 26 5-7. Spot Controls (Optional) 1 Spot/Continuous Switch Use switch to select either an un- timed continuous weld cycle or a timed spot weld cycle. Both weld cycles consist of the following steps: run-in, weld (untimed or spot time), and burnback.
OM-1581 Page 27 5-10. Flowmeter (Optional) CAUTION Wire feeding system is designed for maximum of 50 psi (345 kPa) gas pressure. • Be sure that regulator/flowmeter has preset conditions of no more than 50 psi (345 kPa) gas pressure. 1 Flowmeter 2 V alve Use flowmeter to control shielding ga s flow at the feeder .
OM-1581 Page 28 5-12. Gun Controls 1 Gun T rigger Press trigger to energize welding power source contactor (if applica- ble), start shielding gas flow , and begin wire feed. Fo r shielding gas preflow and post- flow , partially press trigger before and partially release after welding.
OM-1581 Page 29 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance T urn Off all power before maintaining. 3 Months OR Blow Out Or V acuum Inside Replace Unreadable Labels 6 Mont.
OM-1581 Page 30 6-2. Changing Or Cleaning Gun Drive Roll T urn Off wire feeder and welding power source. 1 T op Cover 2 Pressure Roll Assembly Cut of f wire where it enters pressure roll assembly area. 3 Setscrew 4 Current Pick-Up T ab This tab helps prevent burnback caused by welding arcs inside the contact tip.
OM-1581 Page 31 6-3. Changing Feeder Drive Roll And Wire Inlet Guide T urn Off wire feeder and welding power source. Lay wire conduit o ut straight. Open gun pressure roll assembly , and cut welding wire off at contact tip. 1 Pressure Roll Assembly 2 Wire Spool For welding power sources without contactor , retract wire onto spool.
OM-1581 Page 32 6-4. Replacing Or Cleaning Gun Drive Roll Bearing T urn Off wire feeder and welding power source. 1 T op Cover 2 Pressure Roll Assembly 3 Screw 4 Pressure Roll Remove as shown. Use a wire brush to clean bearing. Reinstall with washers, and tighten screw .
OM-1581 Page 33 6-6. Changing Gun Contact T ip Ref. 150 437-A 2 1 Remove nozzle 1 Nozzle 2 FasT ip Unscrew FasTip. Install new FasTip. 6-7. Removing Diffuser In Air And W ater-Cooled Pistol-Grip Guns W A TER IN GUN P ARTS can cause ELECTRIC SHOCK and can lower weld quality .
OM-1581 Page 34 6-8. Replacing The Liner Y T urn Off welding power source and wire feeder . 1 Drive Roll 2 Collet Nut La y gun cable out straight. Remove drive roll on gun and collet nut on on both ends of liner tube assembly and remove old liner .
OM-1581 Page 35 6-9. Replacing Hub Assembly T urn Off wire feeder and welding power source. Remove gun top cover and open pressure roll assembly as shown in Section 6-4.
OM-1581 Page 36 6-10. Adjusting Hub T ension Turn On welding power source and wire feeder to make this adjustment. 1 Wire Speed Control Adjust control to wire speed for welding. 2 Jog Switch Push up, and then release Jog switch. Hub tension is okay if wire unwinds freely , but wire does not backlash when Jog switch is released.
OM-1581 Page 37 6-13. T roubleshooting A. Wire Feeder T rouble T rouble Remedy Pressing gun trigger does not energize feeder . Welding wire is not energized. Shielding gas flows. Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 4-6).
OM-1581 Page 38 B. Gun Trouble T rouble Remedy No weld output; gun/feeder does not work. Secure 1 15 V AC input plug in 1 15 volts ac receptacle (see Section 4- 1 1). Place Power switch on welding power source in the On position. Erratic weld output. Tighten and clean all connections.
OM-1581 Page 39 SECTION 7 − ELECTRICAL DIAGRAMS Figure 7-1. Circuit Diagram For Wire Feeder 156 399-C.
OM-1581 Page 40 195 712-B Figure 7-2. Circuit Diagram For Gun.
OM-1581 Page 41 Notes.
OM-1581 Page 42 SECTION 8 − P ARTS LIST 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 17 19 20 21 22 23 24 25 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 60 59 61 62 71 Fig 8-2 72 73 74 75 76 77 78 79 Figure 8-1.
OM-1581 Page 43 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 089 572 Catch, Link-lock 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1581 Page 44 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly (Continued) Quantity 50 1 1 1 152 Skid, Base 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1581 Page 45 Description Part No. Dia. Mkgs. Item No. Figure 8-2. Motor & Wire Drive (Fig 8-1 Item 71) Quantity 1 1 15 191 Drive Assembly , Wire (Consisting Of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1581 Page 46 1 2 3 4 5 6 7 8 See Fig 8-1 Item 59 10 12 13 14 15 16 17 18 19 20 21 22 23 9 11 PC2 PC4 . Hardware is common and not available unless listed.
OM-1581 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 8-3. Panel, Front w/Components (Fig 8-1 Item 59) Quantity 1 ♦ 1 1 1 569 Meter , Flow 6-60 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1581 Page 48 Figure 8-4. Exploded View Of Gun *Includes Items 24 & 37 . Hardware is common and not available unless listed. 803 706-C 38(Fig. 8-5) 47 46 45 44 50 30 48 51 52 1 27 37 36 35 34 29.
OM-1581 Page 49 Description Part No. Dia. Mkgs. Item No. Figure 8-4. Exploded View Of Gun Quantity 1 214 745 Cover 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1581 Page 50 Description Part No. Dia. Mkgs. Item No. Figure 8-4. Exploded View Of Gun (Continued) Quantity 25 1 12 896 Spring, Cprsn .240 Od X .020 Wire X .437 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1581 Page 51 Ref. 800 434-G . Hardware is common and not available unless listed. 1 2 5 3 4 6 7 8 17 9 10 17 11 12 1 2 3 4 13 14 15 8 16 Figure 8-5.
OM-1581 Page 52 SECTION 9 − P ARTS LIST INCLUDING CONSUMABLES Item Number 12 3 4 5 Ref. 803 909-A / 803 932 / 803 933 / 803 934 6.0” STRAIGHT (#221 087) 6.0” STRAIGHT (#221 519) .030 − 1/16” WIRE .030 − 1/16” WIRE .035 − 1/16” WIRE .
OM-1581 Page 53 Description Part No. Item No. Figure 9-1. Consumables Flowchart Quantity T able 9-1. Nozzles 1 ♦ 176238 Nozzle, Spot Flat (Requires Dif fuser 209099, Used With Any . . . . . . . . . . . . . . Heavy Duty FasT ip t Contact T ip) 1 . . .
OM-1581 Page 54 Description Part No. Item No. Figure 9-1. Consumables Flowchart (Continued) Quantity T able 9-5. V alue Multi − T urn Contact Tips* 2 ♦ 071 825 .030 in (0.9 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters.
An important point after buying a device Miller Electric XR A (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric XR A yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric XR A - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric XR A you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric XR A will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric XR A, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric XR A.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric XR A. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric XR A along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
