Installation | Miller Electric XR W, XR A guide

SECTION 4 − INSTALLATION

NOTE

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.

Review Section 4-1through Section 4-4to determine how equipment will be connected. Air-cooled models are shown in Section 4-1through Section 4-4. For water-cooled models, supplied water hoses must be connected from wire feed- er to coolant supply.

Read entire Section 4 before installing equipment.

4-1. Connections With A CC, CV Or CC/CV Voltage Welding Power Source Having A 14-Socket Receptacle

1

2

1Constant Current (CC), Constant Voltage (CV) Or Constant Current/Constant Voltage (CC/CV) Welding Power Source

2115 VAC/Contactor Control

14-Pin Plug

3Workpiece

4Voltage Sensing Lead

Connect lead to workpiece for CC welding only.

5 Gun

8	6 Wire Feeder

7 115 VAC/Contactor Control

Cord

8 Gas Cylinder

3

4

5

7

6

151 774-F

OM-1581 Page 10

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Miller Electric XR W, XR A manual Installation

Contents

Description OM-1581137 532YProcesses File MIG Gmaw From Miller to You Table of Contents Troubleshooting Spot Controls Optional Arc Welding Hazards Symbol UsageMarks a special safety message Electric Shock can kill Flying Metal can injure eyes ARC Rays can burn eyes and skinWelding can cause fire or explosion Buildup of GAS can injure or kill California Proposition 65 Warnings About Pacemakers Principal Safety StandardsEMF Information Indique un message de sécurité particulier UNE Décharge Électrique peut entraîner la mortLES Fumées ET LES GAZ peuvent être dangereux DES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer unIncendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures graves ’EMPLOI Excessif peut SUR Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessures Principales normes de sécurité En ce qui concerne les stimulateurs cardiaques Gun Specifications − SpecificationsWire Feeder Specifications Duty Cycle And Overheating − Installation Constant Voltage CV Weld- ing Power Source Plug Push door back into original posi- tion to close Removing Top Cover Of Pistol Grip GunTop Cover Triangular Boss Air-Cooled Gun Connections Water-Cooled Gun Connections Air-Cooled Feeder Connections Regulator Return Fitting On Water-Cooled Feeder ConnectionsTop View Rear Panel Supply Fitting On Regulator Reinstall right side panel Voltage Sensing Lead Connections 11 VAC/Contactor Control Plug Information Receptacle on welding power Pins a & B of PLG5Or -4, install 5-pin or Source, and install plug onto Installing Wire Spool Threading Welding Wire Through Feeder Threading Welding Wire Through Gun Coolant Guidelines Adjusting Wire Feed Starting Speed Front Panel Controls Of Feeder Air-Cooled Model Shown Safety Equipment− Operation Work And Voltage Sensing Cable Clamps Run-In Speed Control Jog SwitchVoltage/Wire Speed Switch And Meter Optional Remote Voltage Control Optional Power SwitchSpot Controls Optional Flowmeter Optional Internal Controls Coolant Supply For Water-Cooled Models Only Gun ControlsShielding Gas Sequence Of Gas Metal Arc Welding Gmaw − Continuous Or Spot Turn Off all power before maintaining − Maintenance & TroubleshootingRoutine Maintenance Months Changing Or Cleaning Gun Drive Roll Changing Feeder Drive Roll And Wire Inlet Guide Close pressure roll assembly. Close and latch door Changing Gun Contact Tip Removing Diffuser In Air And Water-Cooled Pistol-Grip Guns Split End Turn Off welding power source and wire feederReplacing The Liner Drive Roll Collet Nut Replacing Hub Assembly Close gun pressure roll assembly and reinstall gun cover Overload Protection Adjusting Hub TensionWater Flow Switch Optional For Water-Cooled Models Troubleshooting Wire Feeder Trouble Gun Trouble Reinstall current pick-up tab if applicable see SectionFilter, and clean fittings see Section − Electrical Diagrams Circuit Diagram For Wire Feeder Circuit Diagram For Gun OM-1581 45 46 − Parts List12 13 9 10 17 18 17 Dia Part Description Quantity Mkgs CB1 Motor & Wire Drive -1 Item Includes Items Panel, Front w/Components Water-Cooled Model Illustrated Panel, Front w/Components -1 Item Includes 38FigItems 24 PLG20 136 Head Tube Assembly Of Pistol-Grip Gun − Parts List Including Consumables Number Tapered FasTipt Contact Tips Heavy Duty FasTiptContact TipsExtra Heavy Duty FasTiptContact Tips Barrel Assemblies Gas DiffusersInsulators Head Tube Assemblies Support ServiceYour distributor also gives For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s