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Miller XR-ALUMAFEED, Owner'S Manual

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Miller XR-ALUMAFEED Owner'S Manual Download Page 39

OM-239 210 Page 35

Diagram

marking

Item

No.

Part

No.

Description

Quantity

Figure 10-1. Main Assembly

1

089 572

Catch, Link-lock

2

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

2

240 263

Label, Set

−

Up Procedure

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

3

223 814

Label, Warning General Precautionary

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

4

+169 085

Wrapper

1

. . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5

208 015

Handle, Rubberized Carrying

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

6

058 427

Ring, Retaining Spool

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

7

057 745

Spring, Cprsn 2.305 Od X .090 Wire X 2.500 Pld

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . 

8

605 518

Bolt, Stl Tap Hexhd .250

−

20x1.250 Gr5 Pld Full Thd

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . 

9

602 233

Washer, Flat Stl .250 Id X .875 Od X .062Thk

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . 

10

057 543

Spring, Cprsn .845 Od X .091 Wire X 1.500

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . 

11

113 168

Washer, Locking

2

. . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

12

058 428

Hub, Spool

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

13

058 628

Washer, Brake Stl

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14

058 424

Washer, Fbr Brake

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15

151 697

Strip, Brake Surface Anti-turn

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

16

112 198

Shroud, Spool Wire 12 In

1

. . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17

057 357

Bushing, Snap-in Nyl .937 Id X 1.125Mtg Hole

2

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . 

18

010 494

Bushing, Snap-in Nyl 1.375 Id X 1.750Mtg Hole

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . 

19

S1

111 997

Switch, Rocker Spst 10A 250VAC

1

. . 

. . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20

PC5

239 921

Circuit Card Assy, 14 Pin Filter HF (ROHS)

1

. . 

. . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . 

21

139 041

Bushing, Strain Relief .450/.709 Id X1.115 Mtg Hole

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . 

22

239 885

Cable, Power

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

23

PLG12

141 162

Housing Plug+Pins, (Service Kit)

1

. . 

. . . 

. . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

24

079 739

Clamp, Cable Strain Relief

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

163 520

Cable, Port No 18

−

14 11/C Type Awm 2

−

14 9

−

18 Cndct

11Ft

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . 

25

211 989

Fitting, W/Screen

1

. . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

26

183 914

Blank, Snap

−

in Nyl 1.250 Mtg Hole Black

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

27

220 805

Nut, 750

−

14 Nps 1.48Hex .41H Nyl

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

28

073 302

Bearing, Ball Rdl Sgl Row .669 X 1.378 X .39

2

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . 

29

113 161

Block, Bearing Front

2

. . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

30

113 165

Stand-Off, .250-20 X 1.000 Lg

4

. . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

31

120 396

Shaft, Spool

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

32

MP1

163 304

Brake, W/Terminals

1

. . 

. . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

33

113 900

Block, Bearing Rear

1

. . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

34

GS1

228 036

Valve, 24VAC 1Way .750

−

14 Thd 2mm Orf 100PSI

1

. . 

. . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . 

35

149 332

Clamp, Hose  .405 

−

 .485 Clp Dia Slfttng Olive Dra

4

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . 

36

176 357

Hose, Sae .187 Id X .410 Od X 21.000

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

37

200 814

Hose Assy, Sae .187 Id X .410 Od X 17.000 W/Clamps

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . 

134 834

Hose, Sae .187 Id X .410 Od (Order By Ft)

4Ft (1.2 m)

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . 

38

112 090

Ftg, Pipe Brs Elbow 1/8 Npt X 3/16 Hose

2

. . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

39

PC1

237 812

Circuit Card Assy, Motor Control W/Program

1

. . 

. . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . 

40

154 408

Bushing, Snap

−

in Nyl .562 Id X .875 Mtg Hole Cent

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . 

41

223 343

Clip, Wire Stdf .40

−

.50 Bndl .156Hole .031

−

.078Thk

3

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . 

42

105 567

Skid, Base

2

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

43

030 170

Bushing, Snap

−

in Nyl .750 Id X 1.000 Mtg Hole

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . 

44

+239 203

Cabinet, Control

1

. . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

45

090 439

Label, Warning Electric Shock Can Kill

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

46

089 573

Plate, Keeper Link

−

lock

2

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

47

♦

173 259

Insulator, Water Fitting

2

. . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

48

♦

139 678

Fitting, Water (Supplied With Water-cooled Gun)

2

. . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . 

49

PC3

239 926

Circuit Card Assy, 10 Pin Filter HF (ROHS)

1

. . 

. . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . 

50

♦

605 798

Washer, Shldr.168id 0.375odx.047T .246odx.030T Nyl

8

. . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . 

51

S2

200 295

Switch, Rocker Spdt 15A 12V (ON)

−

OFF

−

(ON)

1

. . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . 

52

239 940

Bushing, Insulating Gun

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

53

Fig 10-3

Panel, Front W/Components

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

54

Fig 10-2

Motor & Wire Drive

1

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

55

111 569

Meter, Flow 6

−

60 Scfh Of CO2 Scale

1

. . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

56

134 058

Stand

−

Off Support, PC Card .156 Dia W/P&L .375

2

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . 

57

083 147

Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High

4

. . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . 

Summary of Contents for XR-ALUMAFEED

Page 1: ...XR AlumaFeed Processes Description OM 239 210A 2009 01 MIG GMAW Welding Wire Feeder And Feeder Gun File MIG GMAW Visit our website at www MillerWelds com...

Page 2: ...tinue 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...

Page 3: ...ns 13 SECTION 5 INSTALLATION 13 5 1 Connections With A Constant Voltage CV Or Constant Current Constant Voltage CC CV Welding Power Source Having A 14 Socket Receptacle 13 5 2 Air Cooled Feeder Connec...

Page 4: ......

Page 5: ...cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in...

Page 6: ...dden side D Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain fl...

Page 7: ...ding wire MOVING PARTS can cause injury D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors pan...

Page 8: ...York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 91...

Page 9: ...source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivantes...

Page 10: ...de protection Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites peu provoquer leur clatement Des tincelles peuven tre projet es de l arc de soudure La proje...

Page 11: ...e pour usage ult rieur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteil...

Page 12: ...de provoquer des interf rences D L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur t...

Page 13: ...O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Consid r...

Page 14: ...OM 239 210 Page 10...

Page 15: ...g fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can...

Page 16: ...Definitions Some symbols are found only on CE products A Amperes V Volts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz Circuit Breaker Wire Feed Jog Output Trigger Gun Press To Se...

Page 17: ...1 6 mm Max Spool Capacity 12 in 305 mm 400 A 100 Duty Cycle Length 21 1 4 in 540 mm Width 9 1 2 in 241 mm Height 16 in 406 mm 42 5 lb 19 2 kg System Duty Cycle is Limited to Gun Rating SECTION 5 INSTA...

Page 18: ...epare weld cable according to welding power source manual 3 Weld Cable Grommet 4 Current Sensing Reed Relay 5 Weld Cable Terminal In Feeder Route one end of weld cable through grommet through reed rel...

Page 19: ...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 th...

Page 20: ...lding power source 6 Coolant Hose Grommet 7 Location Of Coolant Fittings On Front Panel Route one end of a coolant hose through grommet and connect to rear of Coolant Out fitting in feeder Connect rem...

Page 21: ...4 Gun Bushing 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 Conn...

Page 22: ...0 to 10 volts DC 1 volt per 10 arc volts F Current feedback 0 to 10 volts DC 1 volt per 100 amperes L 0 to 10 volts DC output signal from wire feeder to power source with respect to socket N N Feeder...

Page 23: ...150 mm 1 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 unravelin...

Page 24: ...Menu Indicator 9 Start Menu Indicator 10 Left Display 11 Lock Indicator 12 Setup Menu Indicator 13 Right Display 14 Schedule B Indicator 15 Advanced Trigger Indicator 16 Wire Speed Indicator 17 Amps I...

Page 25: ...ter are automatically active and cannot be turned off in 4T mode In 4T mode press and hold the gun trigger to begin welding at the Start parameter settings Release the gun trigger and welding will con...

Page 26: ...Pulsed MIG welding the selected DISP parameter ARC L or VOLT is lit under the Left Dis play and the WIRE SPEED INDICATOR is lit under the Right Display The arc length or voltage is adjusted using the...

Page 27: ...rigger hold time is always 4 0 seconds after the trigger hold delay time For Example if the trigger hold delay time is set to 2 0 seconds the trigger must be held for at least 2 0 seconds and re lease...

Page 28: ...he gun to the feeder and thread the wire thru the con tact tip Set the drive roll tension setting to 3 4 see Section 5 8 Press and hold the gun trigger The feeder will begin feeding wire with the powe...

Page 29: ...ed used during the Start Time This setting is a percentage of the wirefeed speed the unit is set to for welding Range of this setting is from X0 5 to X2 50 Example If the weld wirefeed speed is 200 an...

Page 30: ...the wirefeed speed the unit is set to for welding Range of this setting is from X0 30 to X1 00 Example If the weld wirefeed speed is 200 and WFS is X0 50 the Crater Wirefeed Speed is 100 Crater Arc L...

Page 31: ...or off Profile Pulse Frequency P FRQ Sets the spacing between ripples in the weld bead Range of this setting is from 0 1 to 5 0 pulses per second See Figures 1 and 2 below Profile Pulse Wirefeed Speed...

Page 32: ...ol 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 Washers Use wire brush to clean idler 7 Outlet Guide 8 Wire Inlet...

Page 33: ...the purge switch is held when the feeder is powered up The error may be cleared by releasing the purge switch COOL ERR Indicates a water flow switch error A water flow switch error occurs if no water...

Page 34: ...e contact tip Verify proper wire size is selected see Section 7 2 Check drive roll pressure in wire feeder and gun see Section 5 8 Check and replace liner if necessary Wire does not feed burnback in c...

Page 35: ...OM 239 210 Page 31 Notes...

Page 36: ...OM 239 210 Page 32 SECTION 9 ELECTRICAL DIAGRAMS Figure 9 1 Circuit Diagram For Wire Feeder...

Page 37: ...OM 239 210 Page 33 239 209 B...

Page 38: ...not available unless listed 242 437 A 54 Figure 10 2 53 Figure 10 3 1 2 3 4 5 6 7 9 10 11 12 13 14 15 17 18 19 21 22 23 24 27 29 30 31 32 28 33 39 41 38 40 43 42 45 44 51 55 56 59 60 61 28 16 34 35 36...

Page 39: ...8Hex 41H Nyl 1 28 073 302 Bearing Ball Rdl Sgl Row 669 X 1 378 X 39 2 29 113 161 Block Bearing Front 2 30 113 165 Stand Off 250 20 X 1 000 Lg 4 31 120 396 Shaft Spool 1 32 MP1 163 304 Brake W Terminal...

Page 40: ...displaying a precautionary label the label should also be ordered Part of 194 146 KIT Water Connection Recommended Spare Parts To maintain the factory original performance of your equipment use only...

Page 41: ...17 058 549 Guide Wire Inlet 1 16 1 18 602 306 Pin Spring Cs 125 X 500 2 19 189 823 Insulator Front Bearing 1 20 189 920 Gear Assy Shaft Bearing 1 21 189 605 Bearing Assy Upper Drive Shaft 1 22 192 929...

Page 42: ...0 28 69Hex 28H Brs Conical Knurl 2 3 Nameplate Order By Model And Serial Number 1 4 239 217 Panel Front 1 5 231 470 Nut Adapter Encoder Shaft Mtg 375 32 To 500 28 2 6 190 512 Stand off No 6 32 X 640 L...

Page 43: ...s MIG Guns and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Sp...

Page 44: ...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 Equip...

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