Miller-electric XR Control Instrukcja Użytkownika

XR ControlXR Air- And Water-Cooled Guns™™ProcessesDescriptionOM-1594 181 715ZMay 2005MIG (GMAW) WeldingWire Feeder And Feeder GunVisit our website a

OM-1594 Page 41-5. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Documents (

OM-1594 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONsom _3/05Y Avertissement : se protéger et protéger les autres contre le risque

OM-1594 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles

OM-1594 Page 72-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenanceRisque D’INCENDIE OU D’EXPLO-SION.D Ne

OM-1594 Page 82-5. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Documents

OM-1594 Page 9SECTION 3 − DEFINITIONS1 1.1 1.2 1.33 3.1 3.2 3.34 4.1+22.12.2++56+2.3S-178 936A. Warning! Watch Out! Thereare possible hazards asshown

OM-1594 Page 101 Read the Owner’s Manual.2 Do not overtighten wire spoolbrake pressure. Tighten onlyuntil wire does not overspoolfrom wire supply spoo

OM-1594 Page 113-3. Symbols And DefinitionsSome symbols are found only on CE products.NoteAAmperesVVolts Alternating CurrentXDuty CycleIPDegree OfProt

OM-1594 Page 124-2. Duty Cycle And OverheatingDuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.Y Exceeding

OM-1594 Page 13SECTION 5 − INSTALLATIONBe sure that contact tip, liner, and drive rolls are correct for wire size and type. SeeParts List to change pa

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-1594 Page 145-2. Air-Cooled Feeder ConnectionsRef. 801 578-A1 Gas FittingRoute one end of 10 ft (3 m) gashose to rear of unit, and connecthose to g

OM-1594 Page 155-3. Air-Cooled Gun ConnectionsRef. 801 577-A / 801 564-E / Ref. 151 666-G1 Gun Control CableInsert plug into Gun Controlreceptacle, an

OM-1594 Page 165-4. Water-Cooled Feeder ConnectionsRef. 152 431-A / Ref. 801 578-AObtain coolant supply.1 Gas FittingRoute one end of 10 ft (3 m) gash

OM-1594 Page 175-5. Water-Cooled Gun ConnectionsRef. 801 577-A / 801 563-D / Ref. 151 666-G1 Gun Control CableInsert plug into Gun Controlreceptacle,

OM-1594 Page 185-6. 14-Pin Plug InformationPin* Pin InformationA 24 volts ac with respect to socket G.B Contact closure to A completes 24 volts ac con

OM-1594 Page 195-8. Meter Circuit Board SettingsRef. 802 359 / Ref. 186 266Tools Needed:1/4 in1 Meter Board PC22 DIP Switch S2Set DIP switch S2 for ty

OM-1594 Page 205-9. Opening Top Cover Of XR-Edge Gun1 Top CoverSqueeze sides of cover to releaseclips and lift up as shown.To close cover, pivot cover

OM-1594 Page 215-11. Installing Wire SpoolRef. 801 578-A / Ref. 072 573-B / Ref. 801 556-C / Ref. 151 599-F1 Wire Spool2 Top Cover3 Pressure Roll Asse

OM-1594 Page 225-12. Threading Welding Wire Through FeederRef. 802 193-ATools Needed:Pull and hold wire; cut off end.Hold wire tightly to keepit from

OM-1594 Page 235-13. Threading Welding Wire Through GunRef. 802 193-A / 801 556-B / 151 599-FTools Needed:Refer to Section 5-12 for instructions on fe

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbo

OM-1594 Page 245-14. Adjusting Wire Feed Starting SpeedTo adjust wire feed starting speed,proceed as follows:1 Motor Speed Control BoardPC12 Motor Sta

OM-1594 Page 255-15. Setting Switches For Preflow And Postflow. Unit arrives from the factorywith preflow Off and postflowturned On.To set switches fo

OM-1594 Page 265-16. Adjusting Trigger Hold Actuation TimeTo adjust trigger hold actuationtime, proceed as follows:1 Motor Speed Control BoardPC12 Pot

OM-1594 Page 27SECTION 6 − OPERATION6-1. Controls801 5541 Voltage/Wire Speed Meter2 Voltage/Wire Speed SwitchWhen switch is in Voltage position, andop

OM-1594 Page 286-2. Internal ControlsRef. 801 578Open left side door.1 Run-In Speed ControlUse this control to set run-in wirefeed speed before arc in

OM-1594 Page 296-3. Gun Controls1 TriggerPress trigger to energize weldingpower source contactor (ifapplicable), start shielding gas flow,and begin wi

OM-1594 Page 306-6. Sequence Of Gas Metal Arc Welding (GMAW) − Continuous Or SpotBegin Weldingssb6.1* 9/92Install &ConnectEquipmentPut OnPersonal

OM-1594 Page 317-1. Feeder Drive Assembly Maintenance802 193-ARetract wire onto spool.1 Pressure Roll Assembly2 Drive Motor Shaft3 Drive Roll4 ScrewUs

OM-1594 Page 327-2. Gun Drive Assembly Maintenance For An XR-Edge GunRef. 801 556-CRetract wire onto spool.1 Screw2 Drive RollUse wire brush to clean

OM-1594 Page 337-3. Replacing Head Tube Liner In XR-Edge GunsRef. 801 556-C. Turn OFF coolant supply beforeremoving head tube onwater-cooled gun.The s

TABLE OF CONTENTSSECTION 7 − MAINTENANCE & TROUBLESHOOTING 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-1594 Page 34Ref. 151 599-F / Ref. 801 556-C / 801 564−E / Ref. 151 666-G / Ref. 200 3717-4. Replacing The LinerY Turn Off welding powersource and w

OM-1594 Page 357-5. Changing Gun Contact TipRef. 150 437-A21Remove nozzle1 Nozzle2 FasTipUnscrew FasTip.Install new FasTip.7-6. Replacing Or Cleaning

OM-1594 Page 36Turn Off wire feeder and weldingpower source.1 Top Cover2 Pressure Roll Assembly3 Screw4 Pressure RollRemove as shown.Use a wire brush

OM-1594 Page 377-9. Removing Diffuser In Air And Water-Cooled Pistol-Grip GunsWATER IN GUN PARTS can cause ELECTRIC SHOCK and can lower weld quality.•

OM-1594 Page 387-10. Replacing Hub Assembly801 577 / Ref. 143 223-ARemove gun top cover and releasepressure arm (see Sections 5-9and 5-10).Retract wir

OM-1594 Page 397-11. Overload ProtectionRef. 801 577 / Ref. 800 185-AY Turn Off wire feeder andwelding power source. Stopengine on weldinggenerator.If

OM-1594 Page 407-13. TroubleshootingY Disconnect power before troubleshooting.Trouble RemedyPressing gun trigger does not energizefeeder. Welding wire

OM-1594 Page 41Notes

OM-1594 Page 42SECTION 8 − ELECTRICAL DIAGRAMSFigure 8-1. Circuit Diagram For Wire Feeder

OM-1594 Page 43218 814-B

dec_con1_11/02Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating la

OM-1594 Page 44218 815-AFigure 8-2. Circuit Diagram For XR Edge Gun198 344-AFigure 8-3. Circuit Diagram For XR Pistol Grip Gun

OM-1594 Page 45Notes

OM-1594 Page 46SECTION 9 − PARTS LIST. Hardware is common andnot available unless listed.802 230-C49 − Figure 9-245 − Figure 9-31234678910111213141516

OM-1594 Page 47DiagrammarkingItemNo.PartNo. Description QuantityFigure 9-1. Main Assembly1 089 572 Catch, Link-lock 2. . . . . . . . . . . . . . . .

OM-1594 Page 48DescriptionFigure 9-1. Main Assembly (Continued)DiagrammarkingItemNo.PartNo. Quantity54 ♦028 770 Potentiometer, Cp Std Slot 1t 2w 1m 1.

OM-1594 Page 49DescriptionFigure 9-2. Motor & Wire Drive (Figure 9-1 Item 49)DiagrammarkingItemNo.PartNo. Quantity1 193 186 Drive Assembly, Wire (

OM-1594 Page 50. Hardware is common andnot available unless listed.802 236-ASee Figure 9-1Item 4512367 8910111213121415161817544Figure 9-3. Panel, Fro

OM-1594 Page 51DescriptionFigure 9-3. Panel, Front w/Components (Figure 9-1 Item 45)DiagrammarkingItemNo.PartNo. Quantity1 ♦111 569 Meter, Flow 6-60 1

OM-1594 Page 5227. Hardware is common andnot available unless listed.Ref. 802 328-H 1234567891011121516172123242526282930313233343536383940374

OM-1594 Page 53DescriptionFigure 9-4. Exploded View Of XR-Edge GunItemNo.PartNo. Quantity1 187 000 Cover,Handle 1. . . . . . . . . . . . . . . . .

OM-1594 Page 54DescriptionFigure 9-4. Exploded View Of XR-Edge Gun (Continued)ItemNo.PartNo. Quantity36 135 773 Knob, Adjust Tension Thumb 1. . . . .

OM-1594 Page 55. Hardware is common andnot available unless listed.802 253-DAir Gun BarrelWater Gun Barrel12345678910111215141343211112Figure 9-5. Bar

OM-1594 Page 56. Hardware is common andnot available unless listed.Ref. 143 117-N15 (Fig. 9-7)3075696867667258 7073741143456 7118912111013329525565646

OM-1594 Page 57DescriptionFigure 9-6. Exploded View Of Pistol-Grip GunDiagrammarkingItemNo.PartNo. Quantity1 214 745 Cover 1. . . . . . . . . . . . .

OM-1594 Page 58DiagrammarkingItemNo.PartNo. QuantityDescriptionFigure 9-6. Exploded View Of Pistol-Grip Gun (Continued)37 166 412 Hose, Water 14in 1.

OM-1594 Page 59Ref. 800 434-F. Hardware is common andnot available unless listed.12534678179101711121234131415816Figure 9-7. Barrel Assembly Of Pistol

OM-1594 Page 60SECTION 10 − PARTS LIST INCLUDING CONSUMABLESItem Number1234 5Ref. 803 909-A / 803 932 / 803 933 / 803 9346.0” STRAIGHT(#221 087)XR-A S

OM-1594 Page 61DescriptionPartNo.ItemNo.10-1. Consumables FlowchartQuantityTable 10-1. Nozzles1 ♦176238 NOZZLE, spot flat (requires diffuser 209099, u

OM-1594 Page 62DescriptionPartNo.ItemNo.10-1. Consumables Flowchart (Continued)QuantityTable 10-4. Tapered FasTipt Contact Tips*2 ♦209024 .023 in (0.6

NotesOver 80,000 trainedsince 1930!400 Trade Square East, Troy, Ohio 453731-800-332-9448 www.welding.orgStart Your ProfessionalWelding Career Now!

OM-1594 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _3/05Y Warning: Protect yourself and others from injury — read and follow these pr

Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 1/05Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-1594 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Spark

OM-1594 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or