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Miller XR-S Control, Owner'S Manual, Page: 20 / 40

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Miller XR-S Control Owner'S Manual Download Page 20

OM-245777 Page 16

5-3. Air-Cooled Gun Connections

Ref. 246 218-A / 245 945-A / 242 435-A / 151 666-G

1

Gun 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

Summary of Contents for XR-S Control

Page 1: ...R S Control Processes Description OM 245777P 2016 06 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: ...FICATIONS 12 4 1 Serial Number And Rating Label Location 12 4 2 Unit Specifications 12 4 3 Wire Type Size and Feed Speed Table 12 4 4 Environmental Specifications 12 SECTION 5 INSTALLATION 14 5 1 Conn...

Page 4: ...USH PULL WIRE FEEDER 300601 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: ...are at welding voltage during operation keep hands and metal objects away Safe33 2012 05 EnvironmentalProtection Use Period China Safe123 2016 06 Wear hat and safety glasses Use ear protection and but...

Page 15: ...ry Current Water Coolant Output Locked V Volts Hz Hertz Output Increase Spot Weld Time U1 Primary Voltage I2 Rated Current Fuse MIG Start Alternating Cur rent Circuit Breaker Trigger Trigger Hold On P...

Page 16: ...5 lb 19 2 kg System Duty Cycle is Limited to Gun Rating See Section 4 3 for Detailed Wire Type Size and Rated Speed Range 4 3 Wire Type Size and Feed Speed Table Motor Speed Wire Type Wire Size Rated...

Page 17: ...364 This table is prepared in accordance with China SJ T 11364 O 2 5 7 8 9 85 GB T26572 Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below th...

Page 18: ...nd 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 Weld...

Page 19: ...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 20: ...Gun 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 p...

Page 21: ...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 22: ...un 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...

Page 23: ...c 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 pins are not used 3 2 1 6 5 5 7 Installing Wire Spool Ref 246 218 C 072 573 C 1 Wire S...

Page 24: ...6 in 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 unr...

Page 25: ...eed Display Displays preset wire speed in inches per minute The gun wire speed control adjusts wire speed from minimum to maximum setting The wire speed display is for reference only and cannot be cal...

Page 26: ...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 27: ...ings use a small nonconductive screwdriver to set switch SW2 in the posi tions shown in the following tables Preflow Postflow Reinstall side panel Ref 245 952 A 237 820 D 1 Tools Needed Nonconductive...

Page 28: ...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 29: ...or also occurs if the jog switch is held when the feeder is powered up The error may be cleared by releasing the jog switch PURG ERR Indicates a purge switch error A purge switch error occurs if the u...

Page 30: ...Verify proper motor torque switch setting is selected see Section 6 3 No weld output gun feeder does not work Check gun control cable connection on wire feeder front panel see Section 5 3 Erratic wel...

Page 31: ...OM 245777 Page 27 Notes...

Page 32: ...OM 245777 Page 28 SECTION 8 ELECTRICAL DIAGRAMS Figure 8 1 Circuit Diagram For Wire Feeder...

Page 33: ...OM 245777 Page 29 245 790 C...

Page 34: ...nd not available unless listed Ref 245 949 C 27 26 28 29 30 26 31 32 33 34 36 37 35 41 40 39 38 25 24 21 20 19 18 22 23 17 16 58 57 59 56 55 54 53 52 60 7 8 9 10 11 12 13 14 6 5 4 3 2 1 51 Fig 9 2 46...

Page 35: ...k Bearing 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 24V...

Page 36: ...laying a precautionary label the label should also be ordered Part of 194 146 KIT Water Connection Supplied With Water Cooled Guns Recommended Spare Parts To maintain the factory original performance...

Page 37: ...06 Pin Spring Cs 125 X 500 2 19 189823 Insulator Front Bearing 1 20 189920 Gear Assy Shaft Bearing 1 21 189605 Bearing Assy Upper Drive Shaft 1 22 192929 Washer Wave 400id X 672od X 010 St Stl Lbs 1 2...

Page 38: ...plate Order By Model And Serial Number 1 2 239217 Panel Front 1 3 190512 Stand Off No 6 32 X 640 Lg 250 Hex Al Fem 4 4 PC2 245780 Circuit Card Assy User Interface W Program 1 5 072785 Screw 006 32x 37...

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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