Miller XR-15A Owner'S Manual Download Page 3

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TABLE OF CONTENTS

SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING

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1-1.

Symbol Usage

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1-2.

Arc Welding Hazards

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1-3.

Proposition 65 Warnings

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1-4.

Principal Safety Standards

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1-5.

EMF Information

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SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION

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2-1.

Signification des symboles

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2-2.

Dangers relatifs au soudage à l’arc

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2-3.

Proposition californienne 65 Avertissements

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2-4.

Principales normes de sécurité

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2-5.

Informations relatives aux CEM

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SECTION 3 − DEFINITIONS

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3-1.

Additional Safety Symbols And Definitions

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3-2.

Miscellaneous Symbols And Definitions

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SECTION 4 − SPECIFICATIONS

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4-1.

Gun Specifications

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4-2.

Duty Cycle And Overheating

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4-3.

Environmental Specifications

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SECTION 5 − INSTALLATION

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5-1.

Connections With A Constant Current (CC), Constant Voltage (CV) Or Constant Current/Constant
Voltage (CC/CV) Welding Power Source Having A 14-Socket
Receptacle

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5-2.

Air-Cooled Gun Connections

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5-3.

Water-Cooled Gun Connections

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5-4.

Millermatic 350/350P Water Cooled Gun Connections

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5-5.

Threading Welding Wire Through Millermatic 350/350P

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5-6.

Threading Welding Wire Through XR-Control Feeder

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5-7.

Adjusting Tension At Feeder

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5-8.

10-Pin Plug Information

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5-9.

Removing Top Cover Of Pistol Grip Gun

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5-10. Threading Welding Wire Through Gun

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SECTION 6 − OPERATION

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6-1.

Gun Controls

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6-2.

Shielding Gas

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6-3.

Sequence Of Gas Metal Arc Welding (GMAW) − Continuous Or Spot

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6-4.

Coolant Supply For Water-Cooled Models Only

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SECTION 7 − MAINTENANCE & TROUBLESHOOTING

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7-1.

Replacing The Gun Liner

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7-2.

Changing Gun Contact Tip

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7-3.

Replacing Or Cleaning Gun Drive Roll In Pistol-Grip Guns

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7-4.

Replacing Or Cleaning Gun Drive Roll Bearing In Pistol-Grip Guns

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7-5.

Replacing Head Tube Liner In Pistol-Grip Guns

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7-6.

Removing Diffuser In Air And Water-Cooled Pistol-Grip Guns

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7-7.

Troubleshooting

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SECTION 8 − ELECTRICAL DIAGRAMS

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SECTION 9 − PARTS LIST

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SECTION 10 − PARTS LIST INCLUDING CONSUMABLES

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WARRANTY

Summary of Contents for XR-15A

Page 1: ...10 MIG GMAW Welding File MIG GMAW Description Semi Automatic Air Water Cooled MIG GMAW Welding Gun CE 200 Ampere Air Push Pull Welding Gun 400 Ampere Water Push Pull Welding Gun For product information Owner s Manual translations and more visit www MillerWelds com ...

Page 2: ...ontinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operati...

Page 3: ... Having A 14 Socket Receptacle 7 5 2 Air Cooled Gun Connections 8 5 3 Water Cooled Gun Connections 9 5 4 Millermatic 350 350P Water Cooled Gun Connections 10 5 5 Threading Welding Wire Through Millermatic 350 350P 11 5 6 Threading Welding Wire Through XR Control Feeder 12 5 7 Adjusting Tension At Feeder 13 5 8 10 Pin Plug Information 14 5 9 Removing Top Cover Of Pistol Grip Gun 14 5 10 Threading W...

Page 4: ... 95 EC Low Voltage 2011 65 EU Restriction of the use of certain hazardous substances in electrical and electronic equipment Standards IEC 60974 1 2005 Arc welding equipment Part 1 Welding power sources IEC 60974 7 2005 Arc welding equipment Part 7 Torches EN 50445 2008 Product family standard to demonstrate compliance of equipment for resistance welding arc welding and allied processes with the ba...

Page 5: ...rea or use breathing device The recommended way to determine adequate ventilationis to sample for the composition and quantity of fumes and gases to which personnel are exposed D Read and understand the Safety Data Sheets SDSs and the manufacturer s instructions for adhesives coatings cleaners consumables coolants degreasers fluxes and metals WELDING can cause fire or explosion D Do not weld near ...

Page 6: ... Chantilly VA 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Mississauga Ontario Canada L4W 5NS phone 800 463 6727 website www csagroup org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American Nation...

Page 7: ...e de travail ou porter un appareil respiratoire Pour dé terminer la bonne ventilation il est recommandé de procéder à un prélèvementpour la composition et la quantité de fumées et de gaz auxquels est exposé le personnel D Lire et comprendre les fiches de données de sécurité et les instruc tions du fabricant concernant les adhésifs les revêtements les net toyants les consommables les produits de re...

Page 8: ...site www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Mississauga Ontario Canad...

Page 9: ...waste Reuse or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collection facility Contact your local recycling office or your local distributor for further information Safe37 2012 05 3 2 Miscellaneous Symbols And Definitions Some symbols are found only on CE products A Amperes X Duty Cycle U1 Primary Voltage V Volts I2 Rated Welding Current U2 Conventional Load...

Page 10: ...0 Duty Cycle At 250 Amperes Using Argon 4 3 Environmental Specifications A Information On Electromagnetic Fields EMF This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding This equipment is built in accordance with EN 60974 1 and is intended to be used only in an occupational environment where the general public access is pr...

Page 11: ...Or Constant Current Constant Voltage CC CV Welding Power Source Having A 14 Socket Receptacle Ref 151 666 G 250 586 A 804 653 A 245 997 A 3 4 6 Millermatic350P XR D Control 9 1 CV Or CC CV Welding Power Source 2 24 VAC Contactor Control 14 Pin Plug 3 Negative Weld Cable 4 Workpiece 5 Welding Gun 6 Wire Feeder 7 Positive Weld Cable 8 Gas Hose 9 Gas Cylinder Shielding gas pressure not to exceed 100 ...

Page 12: ...Control Cable Insert plug into Gun Control receptacle and tighten threaded collar 2 Gun Power Pin 3 Gun Bushing 4 Gun Securing Knob 5 Drive Casting Loosen gun securing knob and insert gun power pin through gun bushing until it bottoms against drive casting Tighten knob 5 4 1 Left Side 2 3 ...

Page 13: ...hing 5 Drive Casting Loosen gun securing knob and insert gun power pin through gun bushing until it bottoms against drive casting Tighten knob Close and latch door 6 Gun Coolant In Hose Connect to Water Out fitting on feeder left hand threads 7 Gun Coolant Out Hose Connect to Water In fitting on feeder left hand threads 8 Water Cooler Output 9 Water Cooler Input 10 Feeder Coolant Output 11 Feeder ...

Page 14: ...eptacle and tighten threaded collar 4 Water In Hose Connect to coolant supply with supplied coupler and water hose left hand threads 5 Gun Connector Loosen gun securing knob and insert gun connector through Wire opening until it bottoms against block Tighten knob Close and latch door 6 Water Out Hose Connect to coolant supply with supplied coupler and water hose left hand threads 7 Coolant In 8 Co...

Page 15: ...ing Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Set pressure indicator scale to 1 2 lb Ref 803 544 A 218 243 A 218 244 A S 0627 A 1 2 3 4 Pressure Indicator Scale 218243 A IMPORTANT For Aluminum Push Pull welding Thread hub tension nut loosely IMPORTANT For Aluminum Push Pull weldi...

Page 16: ...ded 2 1 1 Cable Assembly Lay cable assembly out straight 2 Jog Switch Push Jog switch up to feed wire through cable assembly 3 Torque Switch Select proper push feeder torque set ting for wire size being used Use low torque for 030 in 0 8mm wire Use high torque for all other wire sizes 3 JOG PURGE Notes ...

Page 17: ... Tension Arm Open tension arm Thread wire thru inlet guide along drive roll groove and into wire conduit Close tension arm Adjust tension as follows Hold wire tightly to keep it from unraveling 1 1 Wire Size Welding Gun Calibration 3 4 3 4 1 2 0 030 0 035 in 0 040 in 3 64 in 1 16 in Tension Settings Install proper size drive rolls ...

Page 18: ...d 0 to 9 volts DC with respect to pin H J Gun sensing resistor with respect to pin H I Not used 5 9 Removing Top Cover Of Pistol Grip Gun 1 Top Cover Triangular Boss Push up on triangular boss to open door Door hinges on handle To open door fully push up on door until it clicks into position If door is pushed too far it will separate from handle If this happens the door can be rein stalled Push do...

Page 19: ...supply before removing head tube on water cooled gun 1 Pressure Roll Assembly Lift arm and open pressure roll assembly 2 Cable Assembly Lay cable assembly out straight Push Jog switch up to feed wire through cable assembly 3 Drive Roll For wire sizes 035 in 0 9 mm and smaller use small groove and 047 in 1 2 mm and 1 16 in 1 6 mm use large groove 4 Contact Tip Manually thread wire along drive roll ...

Page 20: ...rence only 1 2 Ref 151 666 F 6 2 Shielding Gas sb5 1 6 92 S 0621 C Ref 151 666 F 1 Shielding Gas Cylinder 2 Valve 3 Gun Trigger Open valve on cylinder just before welding Gun trigger turns weld output and gas flow on and off see Section 6 1 Close valve on cylinder when finished welding 1 2 3 6 3 Sequence Of Gas Metal Arc Welding GMAW Continuous Or Spot Begin Welding ssb6 1 9 92 Install Connect Equ...

Page 21: ...welding Turn Off coolant supply when finished welding 1 MILLER Low Conductivity Coolant No 043 810 MILLER Aluminum Protecting Coolant No 043 809 Distilled Or Deionized Water OK Above 32 F 0 C GTAW Or Where HF Is Used GMAW Or Where Coolant Contacts Aluminum Parts Or Where HF Not Used Application HF High Frequency Current MILLER coolants protect to 37 F 38 C and resist algae growth Coolant 3 2 ...

Page 22: ...nge Clean l Replace To be done by Factory Authorized Service Agent Daily n Check barrel clamp screws for tightness l Repair Or Replace Cracked Weld Cable Every Month nl Gun Cables Drive Rolls Clean and Tighten Weld Terminals Every 3 Months l Damaged Or Unread able Labels l Damaged Gas Hose nl Cords Every 6 Months Blow out or Vacuum Inside Unit Notes ...

Page 23: ...Cone 8 Wire Collet Nut Remove wire guide cone and wire collet guide from power pin Insert split end of new liner into liner conduit and continue feeding liner through conduit until liner is through power pin assembly and is visible Reinstall wire collet guide at power pin and tighten onto liner Cut liner off flush with wire collet guide Re install wire guide cone Refer to Owner s Manual for instru...

Page 24: ... re moved to provide an insulated drive roll If tab is removed a smaller di ameter contact tip is recom mended See options in Parts List Lightly grease top of tab before rein stalling 5 Drive Roll Use wire brush to clean drive roll Install drive roll with desired groove down and turn drive roll so one setscrew faces flat side of shaft 6 Bearing 7 Liner Line up drive roll groove with bear ing groov...

Page 25: ... 5 Replacing Head Tube Liner In Pistol Grip Guns Ref 803 917 A 250 981 A Turn Off coolant supply before removing head tube on water cooled gun The standard head tube liner will accommodatewire diameters from 030 1 16 wire size When changing wire size change gun drive roll see Section 7 3 1 Cover 2 Screw 3 Clamp Loosen clamp screws and remove clamp 4 Head Tube Remove head tube from gun 5 Liner Pull...

Page 26: ...ing section in welding power source manual Wire feeds erratically Adjust drive roll pressure if necessary see Section 5 6 Clean or replace drive rolls as necessary see Section 7 3 No weld output gun feeder does not work Check gun trigger plug connection on wire feeder front panel see Sections 5 2 and 5 3 Place Power switch on welding power source in the On position Erratic weld output Tighten and ...

Page 27: ...OM 236297 Page 23 SECTION 8 ELECTRICAL DIAGRAMS 198344 B Figure 8 1 Circuit Diagram For XR Pistol Grip Gun Notes ...

Page 28: ...43 Fig 9 2 24 10 9 8 7 2 1 11 3 4 6 20 13 14 15 16 17 21 18 19 27 26 29 28 30 19 64 69 71 72 73 66 46 45 48 49 47 65 60 61 51 50 50 75 63 62 58 59 42 31 32 33 52 53 30 54 55 35 34 15 14 35 20 57 56 41 40 37 38 36 17 18 22 26 5 25 68 74 67 23 12 39 44 76 70 Figure 9 1 Exploded View Of Pistol Grip Gun ...

Page 29: ...1 16 1 229853 Guide Cone Outlet 1 18 191065 Liner Replacement 15 Ft Or 30 Ft XR Guns 1 19 191052 Cable Power Water Out 15Ft 1 19 191053 Cable Power Water Out 30Ft 1 20 M1591 Cable Control 15Ft 1 PLG20 217292 Housing Plug Pins Service Kit 1 20 M1592 Cable Control 30Ft 1 PLG20 217292 Housing Plug Pins Service Kit 1 21 235751 Tubing Silicone Rbr 500 Id X Spool Black 1 22 235225 Strip Cop 010 X 1 500 ...

Page 30: ... Stl Slffmg 3 51 602198 Washer Lock 141 Id Stl Split 1 52 134624 Bearing Flg Nyl 140 Id X 187 Od X 375Flg X 031Thk 2 53 134623 Bearing Idler Roll 1 54 132852 Arm Pressure 1 55 605798 Washer Shldr Nyl 375 Od X 168 Id X 080 2 56 133083 Spring Tension Adj Drive Roll 1 57 144860 Screw Mach Stl Flh 8 32 X 437 1 58 058968 Ring Retainer E 2 59 135474 Pin Hinge 1 60 155565 Screw Thumb 1 134799 O ring 176 ...

Page 31: ...l Pistol 1 7 219796 Head Tube Air Pistol Brazed 1 8 134800 O ring 614 Id X 070cs 2 9 203675 Manifold Water 15W 30W Models Includes 1 10 175946 O ring 614 Id X 070cs 2 11 135128 Screw Cap Stl Sch 6 32 X 1 000 15 30W Models 2 12 231532 Head Tube Assy Water Cooled Pistol HD 15 30W Models Includes 1 13 220209 Jacket Outer Insulating 1 14 220216 Washer Flat 594idx1 375odx 125T Black Vulc Fbr 1 15 22021...

Page 32: ...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 030 1 16 WIRE 231 512 227 749 231 511 XR A Spoolmatic Barrel Assy XR W Barrel Assy 232 284 COLLARED INSULATOR TAPERED INSULATOR STANDARD INSULATOR Figure 10 1 Consumables Flowchart For XR Edge And Pistol Guns ...

Page 33: ...2 And Insulator 209047 Used With Any Tapered FasTipt Contact Tip 1 1 209034 Nozzle Slip On Copper 3 8 In Orifice Tapered Requires Diffuser 209031 Or 209032 And Insulator 209047 Used With Any Tapered FasTipt Contact Tip 1 1 209035 Nozzle Screw On Copper 3 8 In Orifice Tapered Requires Diffuser 227 747 231 511 Or 231 512 Used With Any Tapered FasTipt Contact Tip 1 1 209036 Nozzle Screw On Copper 1 2...

Page 34: ...essed Diffuser Requires Nozzle 209033 or 209034 and insulator 209047 Used With Any Tapered FasTip Contact Tip 1 3 209032 Slip On Flush Diffuser Requires Nozzle 209033 or 209034 and Insulator 209047 Used With Any Tapered FasTip Contact Tip 1 3 209099 Spot Diffuser Requires Spot Nozzle 176238 or176240 or 176242 1 Table 10 7 Insulators 4 232284 Insulator Nozzle Collared Diffuser 1 4 198856 Insulator ...

Page 35: ...uns and Subarc SAW Torches Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine d...

Page 36: ...h your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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