Miller XR-D Control Owner'S Manual Download Page 1

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XR - D Control

™

Processes

Description

OM-245778P

2016−05

MIG (GMAW) Welding

Wire Feeder And Feeder Gun

File: MIG (GMAW)

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

Summary of Contents for XR-D Control

Page 1: ...R D Control Processes Description OM 245778P 2016 05 MIG GMAW Welding Wire Feeder And Feeder Gun File MIG GMAW CE For product information Owner s Manual translations and more visit www MillerWelds com...

Page 2: ...ntinue 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: ...12 4 2 Unit Specifications 12 4 3 Wire Type Size and Feed Speed Table 12 4 4 Environmental Specifications 12 SECTION 5 INSTALLATION 13 5 1 Connections With A Constant Voltage CV Or Constant Current Co...

Page 4: ...USH PULL WIRE FEEDER 300687 Council Directives 2014 35 EU Low Voltage 2014 30 EU Electromagnetic Compatibility 2011 65 EU Restriction of the use of certain hazardous substances in electrical and elect...

Page 5: ...neeling 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 order presented 1 a semiautomaticDC...

Page 6: ...ared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere can contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as clo...

Page 7: ...S can injure 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 panels covers or guards for ma...

Page 8: ...PA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of...

Page 9: ...s dans un environnement humideou si l on porte des v tements mouill s sur des structures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y...

Page 10: ...et des quipements chauds peut provoquer des incen dies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un sur chauffement ou...

Page 11: ...capacit suffisante pour lever l appareil D En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil D Teni...

Page 12: ...American Welding Society Standard AWS A6 0 from Global EngineeringDocuments phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Ass...

Page 13: ...Safe37 2012 05 Safe57 2012 05 Wear dry insulating gloves Do not touch electrode wire with bare hand Do not wear wet or damaged gloves Protect yourself from electric shock by insulating yourself from...

Page 14: ...Welding wire and drive parts are at welding voltage during operation keep hands and metal objects away Safe33 2012 05 Wear hat and safety glasses Use ear protection and button shirt collar Use welding...

Page 15: ...Off Run In Read Instructions Water Coolant Input Press Gas In Circuit Breaker Trigger Trigger Hold On Percent U2 Load Voltage Line Connection Continuous Spot Welding MIG Crater Hz Hertz Output Increas...

Page 16: ...vironmental Specifications A IP Rating IP Rating IP23S This equipment is designed for outdoor use It may be stored but is not intended to be used for welding outside during precipitation unless shelte...

Page 17: ...der and welding power source Stop engine on weld ing generator Do not move or operate equipment where it could tip 1 CV Or CC CV Welding Power Source 2 24 VAC Contactor Control 14 Pin Plug 3 Negative...

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: ...ower 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 remaining...

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: ...source with respect to socket D H Voltage feedback 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 Not used N Not used M Not used The remaining pi...

Page 23: ...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 unraveling 1...

Page 24: ...h Indicator 7 Volts Indicator 8 Crater Menu Indicator 9 Start Menu Indicator 10 Left Display 11 Setup Menu Indicator 12 Right Display 13 Wire Speed Indicator 14 Amps Indicator 15 Right Adjust Knob 16...

Page 25: ...3 1 Motor Torque Switch Use switch to select either HI or LOW torque setting for motor in control box HI torque is recommended for all wires except 0 030 and 0 035 Aluminum 2 Run in Speed Control Use...

Page 26: ...ive Once the trigger hold function is active the wire feeder will continue feeding wire until the trigger is pressed and released again Preflow PRE The amount of time that the shielding gas will flow...

Page 27: ...o change menu item values shown in the RIGHT DISPLAY To exit the START MENU press and re lease the START button Items that can be adjusted in this menu are Start Wirefeed Speed WFS Sets the wirefeed s...

Page 28: ...MENU press and re lease the CRATER button Items that can be adjusted in this menu are Crater Wirefeed Speed WFS Sets the Crater Fill wirefeed speed Crater Voltage VOLT Sets the voltage during the Cra...

Page 29: ...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 30: ...curs if 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 n...

Page 31: ...contact tip Verify proper motor torque switch setting is selected see Section 6 3 Check drive roll pressure in wire feeder and gun see Section 5 8 Check and replace liner if necessary Wire does not f...

Page 32: ...OM 245778 Page 28 SECTION 9 ELECTRICAL DIAGRAMS Figure 9 1 Circuit Diagram For Wire Feeder...

Page 33: ...OM 245778 Page 29 245 790 C...

Page 34: ...ot available unless listed Ref 245 999 C 51 Figure 10 2 50 Figure 10 3 1 2 3 4 5 6 8 9 10 11 12 13 14 16 17 18 20 21 22 23 25 27 28 29 30 26 31 37 39 36 38 41 40 43 42 49 53 54 57 58 59 26 15 32 33 34...

Page 35: ...earing Front 2 28 113165 Stand Off 250 20 X 1 000 Lg 4 29 120396 Shaft Spool 1 30 MP1 251948 Brake Fsbr Reverse Mtg Power Off 24VAC 14 In Lb 1 31 113900 Block Bearing Rear 1 32 GS1 228036 Valve 24VAC...

Page 36: ...precautionary label the label should also be ordered Part of 194146 KIT Water Connection Supplied With Water Cooled Guns Recommended Spare Parts To maintain the factory original performance of your eq...

Page 37: ...Bearing 1 22 189920 Gear Assy Shaft Bearing 1 23 189605 Bearing Assy Upper Drive Shaft 1 24 192929 Washer Wave 400id X 672od X 010 St Stl Lbs 1 25 196613 Case Gear Wire Drive Includes 1 26 196604 Was...

Page 38: ...28H Brs Conical Knurl 2 3 Nameplate Order By Model And Serial Number 1 4 239217 Panel Front 1 5 231470 Nut Adapter Encoder Shaft Mtg 375 32 To 500 28 2 6 190512 Stand off No 6 32 X 640 Lg 250 Hex Al F...

Page 39: ...ns 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 suc...

Page 40: ...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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