Instruction/ maintenance manual of the product XR Control Miller Electric
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XR Control XR Air- And W ater-Cooled Guns ™ ™ Processes Description OM-1594 181 715Z May 2005 MIG (GMAW) W elding Wire Feeder And Feeder Gun Visit our website at www.
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 7 − MAINTENANCE & TROUBLESHOOTING 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Feeder Drive Assembly Maintenance 31 . . . . . . . . . . . . . . . . . . . . . . . . . . .
dec_con1_1 1/02 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Note Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W .
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OM-1594 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 i n the adjoining symbols.
OM-1594 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-1594 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-1594 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-1594 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-1594 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-1594 Page 7 2-3 . Dangers s uppl émentaire s en r el ation avec l’install ation, le f onc t i onnement et l a mainte nance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables.
OM-1594 Page 8 2-5. Princi pales n orm es de sécur ité 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-1594 Page 9 SECTION 3 − DEFINITIONS 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 56 + 2.3 S-178 936 A. W arning! W atch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. W elding wire and drive parts are at welding voltage during operation − keep hands and metal objects clear .
OM-1594 Page 10 1 Read the Owner ’ s Manual. 2 Do not overtighten wire spool brake pressure. Tighten only until wire does not overspool from wire supply spool. 3 Do not overtighten drive roll pressure. Tighten only until drive roll will not slip (motor will not stall) on a stationary wire.
OM-1594 Page 1 1 3-3. Symbols And Definitions Some symbols are found only on CE products. Note A Amperes V V olts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz Circuit Breaker Wire.
OM-1594 Page 12 4-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit and void warranty .
OM-1594 Page 13 SECTION 5 − INST ALLA TION Be sure that contact tip, liner , and drive rolls are correct for wire size and type. See Parts List to change parts as needed. NOTE Many procedures apply to both guns covered in this manual. Where procedures differ , separate instructions are given.
OM-1594 Page 14 5-2. Air-Cooled Feeder Connections Ref. 801 578-A 1 Gas Fitting Route one end of 10 ft (3 m) gas hose to rear of unit, and connect hose to gas solenoid fitting. Connect remaining end of hose to regulator/flowmeter . 2 Weld Cable T o Welding Power Source Select and prepare weld cable according to welding power source manual.
OM-1594 Page 15 5-3. Air-Cooled Gun Connections Ref. 801 577-A / 801 564-E / Ref. 151 666-G 1 Gun Control Cable Insert plug into Gun Control receptacle, and tighten threaded collar .
OM-1594 Page 16 5-4. W ater-Cooled Feeder Connections Ref. 152 431-A / Ref. 801 578-A Obtain coolant supply . 1 Gas Fitting Route one end of 10 ft (3 m) gas hose to rear of unit, and connect hose to gas solenoid fitting. Connect remaining end of hose to regulator/flowmeter .
OM-1594 Page 17 5-5. W ater-Cooled Gun Connections Ref. 801 577-A / 801 563-D / Ref. 151 666-G 1 Gun Control Cable Insert plug into Gun Control receptacle, and tighten threaded collar .
OM-1594 Page 18 5-6. 14-Pin Plug Information Pin* Pin Information A 24 volts ac with respect to socket G. B Contact closure to A completes 24 volts ac contactor control circuit. A J B K I G Circuit common for 24 volts AC circuit. B I C L N H C +10 volts dc output to remote control with respect to socket D.
OM-1594 Page 19 5-8. Meter Circuit Board Settings Ref. 802 359 / Ref. 186 266 T ools Needed: 1/4 in 1 Meter Board PC2 2 DIP Switch S2 Set DIP switch S2 for type of welding power source, and desired wire feed speed d ispl ay . Reinstall hinged door and side panel.
OM-1594 Page 20 5-9. Opening T op Cover Of XR-Edge Gun 1 T op Cover Squeeze sides of cover to release clips and lift up as shown. T o close cover , pivot cover closed on gun, and push cover down until clips lock tight.
OM-1594 Page 21 5-1 1. Installing Wire Spool Ref. 801 578-A / Ref. 072 573-B / Ref. 801 556-C / Ref. 151 599-F 1 Wire Spool 2 T op Cover 3 Pressure Roll Assembly 4 Gun Contact Tip If wire spool is being replaced, open top cover , open pressure roll as- sembly in gun, and cut welding wire of f at contact tip.
OM-1594 Page 22 5-12. Threading W elding Wire Through Feeder Ref. 802 193-A T ools Needed: Pull and hold wire; cut off end. Hold wire tightly to keep it from unraveling. 6 in (150 mm) Open tension arm. Thread wire thru inlet guide, along drive roll groove, and into wire conduit.
OM-1594 Page 23 5-13. Threading W elding Wire Through Gun Ref. 802 193-A / 801 556-B / 151 599-F T ools Needed: Refer to Section 5-12 for instructions on feeding wire through feeder. Lay gun cable out straight. Open top cover , and open pressure roll assembly .
OM-1594 Page 24 5-14. Adjusting Wire Feed Starting Speed T o adjust wire feed starting speed, proceed as follows: 1 Motor Speed Control Board PC1 2 Motor Start Control Potentiometer R3 Remove protective white rubber cap before making adjustment. Adjust potentiometer using a small nonconductive screwdriver .
OM-1594 Page 25 5-15. Setting Switches For Preflow And Postflow . Unit arrives from the factory with preflow Off and postflow turned On. T o set switches for preflow and postflow , proceed as follows: 1 Motor Speed Control Board PC1 2 DIP Switch S1 . Preflow and postflow have pre- set time values and cannot be changed.
OM-1594 Page 26 5-16. Adjusting T rigger Hold Actuation Time T o adjust trigger hold actuation time, proceed as follows: 1 Motor Speed Control Board PC1 2 Potentiometer R50 .
OM-1594 Page 27 SECTION 6 − OPERA TION 6-1. Controls 801 554 1 V oltage/Wire Speed Meter 2 V oltage/Wire Speed Switch When switch is in V oltage position, and operator is welding, meter displays arc voltage. Cable resistance and poor connections may cause displayed voltage to vary slightly from actual voltage at welding arc.
OM-1594 Page 28 6-2. Internal Controls Ref. 801 578 Open left side door . 1 Run-In Speed Control Use this control to set run-in wire feed speed before arc initiation. After arc initiation, weld wire feed speed is controlled by the wire speed setting on the welding gun (see Section 6-3 ).
OM-1594 Page 29 6-3. Gun Controls 1 T rigger Press trigger to energize welding power source contactor (if applicable), start shielding gas flow , and begin wire feed. Switches inside the wire feeder can be set to provide timed shielding gas preflow and postflow when trigger is pressed and released (see Section 5-15 ).
OM-1594 Page 30 6-6. Sequence Of Gas Metal Arc W elding (GMA W) − Continuous Or Spot Begin W elding ssb6.1* 9/92 Install & Connect Equipment Put On Personal Safety Equipment Set Controls Turn On.
OM-1594 Page 31 7-1. Feeder Drive Assembly Maintenance 802 193-A Retract wire onto spool. 1 Pressure Roll Assembly 2 Drive Motor Shaft 3 Drive Roll 4 Screw Use wire brush to clean drive roll. 5 Drive Roll Idler 6 Shoulder W ashers Use wire brush to clean idler .
OM-1594 Page 32 7-2. Gun Drive Assembly Maintenance For An XR-Edge Gun Ref. 801 556-C Retract wire onto spool. 1 Screw 2 Drive Roll Use wire brush to clean drive roll. Install drive roll with hex opening down tow ar d shaft hex, and secure with screw.
OM-1594 Page 33 7-3. Replacing Head T ube Liner In XR-Edge Guns Ref. 801 556-C . T urn OFF coolant supply before removing head tube on water -cooled gun.
OM-1594 Page 34 Ref. 151 599-F / Ref. 801 556-C / 801 564 − E / Ref. 151 666-G / Ref. 200 371 7-4. 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 lin- er tube assembly .
OM-1594 Page 35 7-5. Changing Gun Contact Tip Ref. 150 437-A 2 1 Remove nozzle 1 Nozzle 2 FasT ip Unscrew FasTip. Install new FasTip. 7-6. Replacing Or Cleaning Gun Drive Roll In Pistol-Grip Guns T urn Of f 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.
OM-1594 Page 36 T urn Of f 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 . Close pressure roll assembly .
OM-1594 Page 37 7-9. 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 . • Turn Off welding power source and water supply before working on gun. Stop engine on welding generators.
OM-1594 Page 38 7-10. Replacing Hub Assembly 801 577 / Ref. 143 223-A Remove gun top cover and release pressure arm (see Sections 5-9 and 5-10 ). Retract wire onto spool and remove spool.
OM-1594 Page 39 7-1 1. Overload Protection Ref. 801 577 / Ref. 800 185-A Y T urn Off wire feeder and welding power source. Stop engine on welding generator .
OM-1594 Page 40 7-13. T roubleshooting Y Disconnect power before troubleshooting. T rouble Remedy Pressing gun trigger does not energize feeder . Welding wire is not energized. Shielding gas does not flow Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 5- 3 or 5- 5 as appli- cable).
OM-1594 Page 41 Notes.
OM-1594 Page 42 SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram For Wire Feeder.
OM-1594 Page 43 218 814-B.
OM-1594 Page 44 218 815-A Figure 8-2. Circuit Diagram For XR Edge Gun 198 344-A Figure 8-3. Circuit Diagram For XR Pistol Grip Gun.
OM-1594 Page 45 Notes.
OM-1594 Page 46 SECTION 9 − P ARTS LIST . Hardware is common and not available unless listed. 802 230-C 49 − Figure 9-2 45 − Figure 9-3 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 42 41 43 44 50 51 52 53 57 46 47 48 54 55 56 58 59 25 60 Figure 9-1.
OM-1594 Page 47 Diagram marking Item No. Part No. Description Quantity Figure 9-1. Main Assembly 1 089 572 Catch, Link-lock 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 48 Description Figure 9-1. Main Assembly (Continued) Diagram marking Item No. Part No. Quantity 54 ♦ 028 770 Potentiometer , Cp Std Slot 1t 2w 1m 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 49 Description Figure 9-2. Motor & Wire Drive (Figure 9-1 Item 49) Diagram marking Item No. Part No. Quantity 1 193 186 Drive Assembly , Wire (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 50 . Hardware is common and not available unless listed. 802 236-A See Figure 9-1 Item 45 1 2 3 6 7 8 9 10 11 12 13 12 14 15 16 18 17 5 4 4 Figure 9-3.
OM-1594 Page 51 Description Figure 9-3. Panel, Front w/Components (Figure 9-1 Item 45) Diagram marking Item No. Part No. Quantity 1 ♦ 1 1 1 569 Meter , Flow 6-60 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 52 27 . Hardware is common and not available unless listed. Ref. 802 328-H 1 2 3 4 5 6 7 8 9 10 11 12 15 16 17 21 23 24 25 26 28 29 30 31 32 33 34 35 36 38 39 40 37 41 42 22 44 45 46 47 48 50 51 47 52 17 19 49 16 14 18 20 27 See Figure 9-5 53 54 13 22 26 24 23 25 21 56 55 13 18 43 43 Figure 9-4.
OM-1594 Page 53 Description Figure 9-4. Exploded V iew Of XR-Edge Gun Item No. Part No. Quantity 1 187 000 Cover ,Handle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 54 Description Figure 9-4. Exploded View Of XR-Edge Gun (Continued) Item No. Part No. Quantit y 36 135 773 Knob, Adjust T ension Thumb 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 55 . Hardware is common and not available unless listed. 802 253-D Air Gun Barrel W ater Gun Barrel 1 2 3 4 5 6 7 8 9 10 11 12 15 14 13 4 3 2 1 11 12 Figure 9-5. Barrel Assembly Of XR-Edge Gun Item No. Part No. Quantity Description Figure 9-5.
OM-1594 Page 56 . Hardware is common and not available unless listed. Ref. 143 1 17-N 15 (Fig. 9-7) 30 75 69 68 67 66 72 58 70 73 74 1 14 3 4 5 6 7 11 8 9 12 11 10 13 32 9 52 55 65 64 63 62 61 57 18 16* 17 21 22 20 19 51 56 48 49 50 24 23 23 58 54 53 46 47 76 33 34 35 25 26 6 27 28 38 37 5 4 38 45 44 43 42 40 41 39 7 8 74 14 Figure 9-6.
OM-1594 Page 57 Description Figure 9-6. Exploded V iew Of Pistol-Grip Gun Diagram marking Item No. Part No. Quantity 1 214 745 Cover 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 58 Diagram marking Item No. Part No. Quantity Description Figure 9-6. Exploded View Of Pistol-Grip Gun (Continued) 37 166 412 Hose, W ater 14in 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 59 Ref. 800 434-F . 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 9-7. Barrel Assembly Of Pistol-Grip Gun Item No. Part No. Quantity Description Figure 9-7. Barrel Assembly Of Pistol-Grip Gun (Figure 9-6 Item 15) 1 199 613 Nozzle, Brass 5/8 In Orifice T apered 1 .
OM-1594 Page 60 SECTION 10 − 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) XR-A Spoolmatic Head T ube 6.0” STRAIGHT (#221 519) XR-W Head T ube 6.0” CURVE (#221 514) XR-A Edge Head T ube 6.
OM-1594 Page 61 Description Part No. Item No. 10-1. Consumables Flowchart Quantity T able 10-1. Nozzles 1 ♦ 176238 NOZZLE, spot flat (requires dif fuser 209099, used with any . . . . . . . . . . . . . . heavy duty FasT ip t contact tip) 1 . . . . . .
OM-1594 Page 62 Description Part No. Item No. 10-1. Consumables Flowchart (Continued) Quantity T able 10-4. T apered FasTip t Contact Tips* 2 ♦ 209024 .023 in (0.6 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.weldin g .or g Star t Y our Pr ofessional W eldin g Career Now!.
Notes.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 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. Support Need fast answers to the tough welding questions? Contact your distributor .
PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05 Miller Elect ric Mfg. Co. An Illinois T ool Wor k s Comp any 1635 W es t Spencer St reet Applet on, WI 5 4914 USA International He adquarters − U.
An important point after buying a device Miller Electric XR Control (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 Control 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 Control - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric XR Control 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 Control will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric XR Control, 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 Control.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric XR Control. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric XR Control 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
