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Miller Electric
XR Control manual
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Contents
Main
From Miller to You
Page
TABLE OF CONTENTS
Declaration of Conformity for European Community (CE) Products
Note
Appleton, WI 54914 USA
Page
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING
1-1. Symbol Usage
.
1-2. Arc Welding Hazards
ELECTRIC SHOCK can kill.
ARC RAYS can burn eyes and skin.
WELDING can cause fire or explosion.
FLYING METAL can injure eyes.
BUILDUP OF GAS can injure or kill.
HOT PARTS can cause severe burns.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
FALLING UNIT can cause injury.
OVERUSE can cause OVERHEATING
STATIC (ESD) can damage PC boards.
1-5. Principal Safety Standards
1-6. EMF Information
SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION
2-1. Symboles utiliss
.
2-2. Dangers relatifs au soudage la rc
UNE DCHARGE LECTRIQUE peut entraner la mort.
LES RAYONS DARC peuvent entra- ner des brlures aux yeux et la peau.
LE SOUDAGE peut provoquer un incendie ou une explosion.
DES PARTICULES VOLANTES peuvent blesser les yeux.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou mme la mort.
DES PICES CHAUDES peuvent provoquer des brlures graves.
2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance
Risque DINCENDIE OU DEXPLO- SION.
LA CHUTE DE LAPPAREIL peut blesser.
LEMPLOI EXCESSIF peut SUR- CHAUFFER LQUIPEMENT.
LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.
2-5. Principales normes de scurit
2-6. Information EMF
SECTION 3 DEFINITIONS
3-1. Warning Label Definitions
50/60
3-2. Rating Label For CE Products
S/N:
3-3. Symbols And Definitions
Some symbols are found only on CE products.
AAmperes VVolts Alternating Current XDuty Cycle IP
I 1 Primary Current I
SECTION 4 INTRODUCTION
4-1. Specifications
Type of Input Power Welding Power
4-2. Duty Cycle And Overheating
SECTION 5 INSTALLATION
NOTE
NOTE
5-2. Air-Cooled Feeder Connections
5-3. Air-Cooled Gun Connections
5-4. Water-Cooled Feeder Connections
5-5. Water-Cooled Gun Connections
5-6. 14-Pin Plug Information
Pin* Pin Information
5-7. (Optional) Voltage Sensing Lead Connections And CC/CV Jumper Plug Settings
5-8. Meter Circuit Board Settings
.
5-9. Opening Top Cover Of XR-Edge Gun
5-10. Removing Top Cover Of Pistol Grip Gun
.
5-11. Installing Wire Spool
5-12. Threading Welding Wire Through Feeder
5-13. Threading Welding Wire Through Gun
.
5-14. Adjusting Wire Feed Starting Speed
5-15. Setting Switches For Preflow And Postflow .
.
5-16. Adjusting Trigger Hold Actuation Time
.
SECTION 6 OPERATION
6-1. Controls
.
6-2. Internal Controls
.
6-3. Gun Controls
6-4. Shielding Gas
6-5. Coolant Supply For Water-Cooled Models Only
6-6. Sequence Of Gas Metal Arc Welding (GMAW) Continuous Or Spot
SECTION 7 MAINTENANCE & TROUBLESHOOTING
4 To 6 Weeks
3 Months
6 Months
7-1. Feeder Drive Assembly Maintenance
7-2. Gun Drive Assembly Maintenance For An XR-Edge Gun
.
7-3. Replacing Head Tube Liner In XR-Edge Guns
.
7-4. Replacing The Liner
.
7-5. Changing Gun Contact Tip
7-6. Replacing Or Cleaning Gun Drive Roll In Pistol-Grip Guns
7-7. Replacing Or Cleaning Gun Drive Roll Bearing In Pistol-Grip Guns
7-8. Replacing Head Tube Liner In Pistol-Grip Guns
.
WARNING
7-10. Replacing Hub Assembly
7-11. Overload Protection
7-12. Water Flow Switch (Optional For Water-Cooled Models)
7-13. Troubleshooting
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SECTION 9 PARTS LIST
Figure 9-1. Main Assembly
Page
Page
Page
Figure 9-3. Panel, Front w/Components (Water-Cooled Model Illustrated)
Page
Figure 9-4. Exploded View Of XR-Edge Gun
Page
Page
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Figure 9-6. Exploded View Of Pistol-Grip Gun
Page
Page
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SECTION 10 PARTS LIST INCLUDING CONSUMABLES
Item Number 1234 5
Figure 10-1. Consumables Flowchart
Page
Page
Notes
Page
Warranty Questions?
Call 1-800-4-A-MILLER for your local Miller distributor.
Effective January 1, 2005 (Equipment with a serial number preface of LF or newer)
Please complete and retain with your personal records.
For Service
Always provide Model Name and Serial/Style Number.
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Owners Record