300 Ampere (Air) Push-Pull Welding Gun
400 Ampere (Water) Push-Pull Welding Gun
XR - AlumaPro Plus
(Air And Water-Cooled Guns)
Processes
Description
MIG (GMAW) Welding
OM-245892L
2019−05
Semi-Automatic, Air/Water-
Cooled, MIG (GMAW) Welding
Gun
™
File: MIG (GMAW)
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
CE And Non-CE Models
Miller Electric manufactures a full line
of welders and welding-related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue 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 operation quick
and easy. With Miller, you can count on
years of reliable service with proper
maintenance. And if for some reason the unit
needs repair, there’s a Troubleshooting
section that will help you figure out what the
problem is, and our extensive service
network is there to help fix the problem.
Warranty and maintenance information for
your particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Mil_Thank1
2019−01
TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING 1......
1-1. Symbol Usage 1.......................................................................
1-2. Arc Welding Hazards 1.................................................................
1-3. Proposition 65 Warnings 2...............................................................
1-4. Principal Safety Standards 2.............................................................
1-5. EMF Information 2.....................................................................
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION 3..............................................................................
2-1. Signification des symboles 3.............................................................
2-2. Dangers relatifs au soudage à l’arc 3......................................................
2-3. Proposition californienne 65 Avertissements 4..............................................
2-4. Principales normes de sécurité 4.........................................................
2-5. Informations relatives aux CEM 4.........................................................
SECTION 3 − DEFINITIONS 5..................................................................
3-1. Additional Safety Symbols And Definitions 5................................................
3-2. Miscellaneous Symbols And Definitions 5..................................................
SECTION 4 − INTRODUCTION 6...............................................................
4-1. Specifications 6........................................................................
4-2. Environmental Specifications 6...........................................................
4-3. Duty Cycle And Overheating 7...........................................................
SECTION 5 − INSTALLATION 8................................................................
5-1. Equipment Connection Diagram - Single Feeder 8...........................................
5-2. Equipment Connection Diagram - Dual Feeder 9............................................
5-3. 14-Pin Plug Information For Connecting Wire Feeder To Power Source 10........................
5-4. Opening Top Cover Of XR-AlumaPro Plus Gun 10............................................
5-5. Threading Welding Wire Through Gun 11...................................................
SECTION 6 − OPERATION 12...................................................................
6-1. Gun Controls 12........................................................................
6-2. Gun Pressure Roll Tension Setting 12......................................................
6-3. Shielding Gas 13........................................................................
6-4. Coolant Supply For Water-Cooled Models Only 13............................................
6-5. Gun Drive Assembly Maintenance For An XR-AlumaPro Plus Gun 14...........................
6-6. Replacing Head Tube Liner In XR-AlumaPro Plus Guns 15....................................
6-7. Changing Gun Contact Tip 15.............................................................
6-8. Replacing The Gun Liner On XR-AlumaPro Plus Guns 16.....................................
SECTION 7 − MAINTENANCE & TROUBLESHOOTING 17.........................................
7-1. Routine Maintenance For Aluminum Push/Pull Guns 17.......................................
7-2. Cleaning The Gun Liner On XR-AlumaPro Plus Guns 18......................................
7-3. Troubleshooting Table 19.................................................................
SECTION 8 − ELECTRICAL DIAGRAMS 20.......................................................
SECTION 9 − PARTS LIST 22...................................................................
SECTION 10 − PARTS LIST INCLUDING CONSUMABLES 27.......................................
WARRANTY
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product Stock Number
XR-W ALUMA-PRO 300003, 300004, 300265
XR-W ALUMA-PRO PLUS 300003001, 300004001
Council Directives:
• 2014/35/EU Low Voltage
• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
• IEC 60974-7:2013 Arc welding equipment – Part 7: Torches
Signatory:
_____________________________________ ___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
May 21, 2019
271425C
OM-245892 Page 1
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW
WELDING GUNS − READ BEFORE USING
SR7 (MIG) 2018-01
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the welding power source Owner’s Manual. Read
and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, train-
ing and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recog-
nize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
D Always wear dry insulating gloves.
D Insulate yourself from work and ground.
D Do not touch live electrode or electrical parts.
D Replace worn, damaged, or cracked guns or cables.
D Turn off welding power source before changing contact tip or gun
parts.
D Keep all covers and handle securely in place.
FUMES AND GASES can be hazardous.
D Keep your head out of the fumes.
D Ventilate area, or use breathing device. The
recommended
way to determine adequate
ventilation
is 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.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING can cause fire or explosion.
D Do not weld near flammable material.
D Do not weld on containers that have held com-
bustibles, or on closed containers such as
tanks, drums, or pipes unless they are properly prepared ac-
cording to AWS F4.1 and AWS A6.0 (see Safety Standards).
D Watch for fire; keep extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in
use.
D Always ventilate confined spaces or use ap-
proved air-supplied respirator.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
ARC RAYS can burn eyes and skin.
D Wear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
HOT PARTS can burn.
D Allow gun to cool before touching.
D Do not touch hot metal.
D Protect hot metal from contact by others.
OM-245892 Page 2
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Check for noise level limits exceeding those
specified by OSHA.
D Use approved ear plugs or ear muffs if noise level is high.
D Warn others nearby about noise hazard.
WELDING WIRE can injure.
D Keep hands and body away from gun tip when
trigger is pressed.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
1-3. Proposition 65 Warnings
WARNING: This product can expose you to chemicals in-
cluding lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65W
arnings.ca.gov
.
1-4. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www
.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
site: www.ansi.org).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: 1-877-413-5184, website: www.glo-
bal.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering
Documents (phone: 1-877-413-5184,
website: www
.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
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, 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 National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
site: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Govern-
ment Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OS-
HA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).
1-5. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and induc-
tion heating operations) creates an EMF field around the welding circuit.
EMF fields can interfere with some medical implants, e.g. pacemakers.
Protective measures for persons wearing medical implants have to be
taken. For example, restrict access for passers−by or conduct individu-
al risk assessment for welders. All welders should use the following pro-
cedures in order to minimize exposure to EMF fields from the welding
circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.
OM-245892 Page 3
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES
PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION
SR7(MIG)_2018−01_fre
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris-
ques de danger. Lorsque vous voyez un symbole, soyez vigilant
et suivez les directives mentionnées afin d’éviter tout danger.
Les consignes de sécurité présentées ci-après ne font que résu-
mer l’information contenue dans les normes de sécurité énumé-
rées dans le manuel d’utilisation du poste de soudage. Veuillez
lire et respecter toutes ces normes de sécurité.
L
’installation,
l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une
personne qualifiée est définie comme celle qui, par la
possession
d’un diplôme reconnu, d’un certificat ou d’un
statut professionnel, ou qui, par une connaissance, une for-
mation et une expérience approfondies, a démontré avec
succès sa capacité à résoudre les problèmes liés à la tâche,
le travail ou le projet et a reçu une formation en sécurité afin
de reconnaître et d’éviter les risques inhérents.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
UN CHOC ÉLECTRIQUE peut tuer.
D Porter toujours des gants secs et isolants.
D S’isoler de la pièce et de la terre.
D Ne jamais toucher une électrode ou des pièces
électriques
sous tension.
D Remplacer les pistolets ou câbles de soudage qui sont endom
-
magés, usés ou craquelés.
D Mettre la soudeuse hors tension avant de remplacer un be
c
contact ou des pièces de pistolet.
D S’assurer que tous les couvercles et poignées sont fermemen
t
assujettis.
LES VAPEURS ET LES FUMÉES
peuvent être nocives.
D Éloigner sa tête des endroits renfermant des
vapeurs.
D Aérer la zone de travail ou porter un appareil respiratoire. Pour dé-
terminer la bonne ventilation, il est recommandé de procéder à un
prélèvement
pour 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 refroidissement, les
dégraisseurs,
les flux et les métaux.
LE SOUDAGE peut causer un in-
cendie ou une explosion.
D Ne pas souder à proximité de matériaux inflam-
mables.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Prendre garde aux incendies et toujours avoir un extincteur à
proximité.
D Lire et comprendre les fiches de données de sécurité et les
instructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
L’ACCUMULATION DE VAPEURS
peut causer des lésions ou la mort.
D Quand on n’utilise pas le gaz comprimé de pro-
tection, fermer le robinet de la bouteille.
D Assurer toujours la ventilation des zones fermées ou utiliser un
appareil respiratoire avec alimentation en air.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LE RAYONNEMENT DE L’ARC peut
brûler les yeux et la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
OM-245892 Page 4
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Laisser refroidir le pistolet avant de le toucher.
D Ne pas toucher d’objets métalliques chauds.
D Abriter les objets métalliques contre tout
contact par les personnes à proximité.
Le BRUIT peut endommager l’ouie.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Vérifier si les niveaux de bruit excèdent les lim-
ites spécifiées par l’OSHA.
D Utiliser des bouche-oreilles ou des serre-tête antibruit approuvés si
le niveau de bruit est élevé.
D Avertir les personnes à proximité au sujet du danger inhérent au
bruit.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Éloigner les mains et le corps de la buse du
pistolet après avoir appuyé sur la gâchette.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes
et le Mode d’emploi avant
l’installation,
l’utilisation ou l’entretien de
l’appareil.
Lire les informations de sécurité au
début du manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le cons-
tructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie,
ainsi que les codes municipaux.
2-3. Proposition californienne 65 Avertissements
AVERTISSEMENT : ce produit peut vous exposer à des
produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65W
arnings.ca.gov
.
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www
.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
site: www.ansi.org).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: 1-877-413-5184, website: www.glo-
bal.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering
Documents (phone: 1-877-413-5184,
website: www
.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
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, 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 National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
site: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indust-
ry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, auprès du U.S. Government Printing Office,
Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régiona-
ux––le téléphone de la région 5, Chicago, est 3123532220, site Internet
: www.osha.gov).
2-5. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Le courant
issu d’un soudage à l’arc (et de procédés connexes, y compris le
soudage par points, le gougeage, le découpage plasma et les
opérations
de chauffage par induction) crée un champ
électromagnétique
(CEM) autour du circuit de soudage. Les champs
électromagnétiques
produits peuvent causer interférence à certains
implants médicaux, p. ex. les stimulateurs cardiaques. Des mesures de
protection pour les porteurs d’implants médicaux doivent être prises:
Limiter par exemple tout accès aux passants ou procéder à une
évaluation
des risques individuels pour les soudeurs. Tous les
soudeurs doivent appliquer les procédures suivantes pour minimiser
l’exposition aux CEM provenant du circuit de soudage:
1 Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2 Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3 Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4 Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5 Connecter la pince sur la pièce aussi près que possible de la
soudure.
6 Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7 Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par
induction. Si le médecin approuve, il est recommandé de suivre les pro-
cédures précédentes.
OM-245892 Page 5
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not discard product (where applicable) with general 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 2017−04
3-2. Miscellaneous Symbols And Definitions
A
Amperes
V
Volts
Alternating
Cur-
rent
X
Duty Cycle
Wire Feed
Gun
Trigger Hold Off
Run-In
Read Instructions
Water (Coolant)
Input
Circuit Breaker
Trigger
Trigger Hold On
Percent
U
2
Load Voltage
Line Connection
Continuous
Spot Welding
Hz
Hertz
Output
Increase
Spot Weld Time
U
1
Primary Voltage
I
2
Rated Current
Fuse
IP
Degree Of
Protection
Jog
Press To Set
Purge
Burnback Time
I
1
Primary Current
Water (Coolant)
Output
OM-245892 Page 6
SECTION 4 − INTRODUCTION
4-1. Specifications
Model Welding Output Range Electrode
Wire Diameter
Capacity
Wire Feed
Speed Range
Net Weight
(Torch Only)
XR-A AlumaPro Plus 15 ft (4.7 m)
XR-A AlumaPro Plus 25 ft (7.6 m)
XR-A AlumaPro Plus 35 ft (10.7 m)
300 A at 100% Duty Cycle .030 To 1/16 in.
(0.8 To 1.6 mm)
aluminum wire
70 To 900 ipm
(1.8 To 23 mpm)
2.5 lb (1.1 kg)
(less cables)
(CE And Non CE Models)
XR-W AlumaPro Plus 15 ft (4.7 m)
XR-W AlumaPro Plus 25 ft (7.6 m)
XR-W AlumaPro Plus 35 ft (10.7 m)
400 A at 100% Duty Cycle .030 To 1/16 in.
(0.8 To 1.6 mm)
aluminum wire
70 To 900 ipm
(1.8 To 23 mpm)
2.9 lb (1.3 kg)
(less cables)
. When using 1/16 in. (1.6 mm) wire, kit 230708 must be installed.
4-2. Environmental Specifications
A. IP Rating
IP Rating
IP3X
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP3X 2014−06
B. Temperature Specifications
Operating Temperature Range Storage Temperature Range
14 to 104 °F (−10 to 40°C) −4 to 131 °F (−20 to 55°C)
Temp_2016-07
C. 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 prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S The EMF assessment on this equipment was conducted at 0.5 meter.
S At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
Notes
OM-245892 Page 7
4-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
sduty1 5/95
Air-Cooled Models
Continuous Welding
100% Duty Cycle At 300 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns
Water-Cooled Models (CE)
Continuous Welding
100% Duty Cycle At 400 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns
Notes
OM-245892 Page 8
SECTION 5 − INSTALLATION
. Be sure that contact tip, liner, and drive rolls are correct for wire size and type. See Parts List to change parts as needed.
5-1. Equipment Connection Diagram - Single Feeder
1 Welding Power Source
2 Contactor Control/Power Cord
3 Positive (+) Weld Cable
4 Negative (−) Weld Cable
5 Workpiece
6 Welding Gun
7 Wire Feeder
8 Gas Hose
9 Gas Cylinder and Regulator
(Customer Supplied)
. Shielding gas pressure not to
exceed 100 PSI (689 kPa).
10 Coolant Hoses - Water−
cooled Guns Only
246040-A
1
2
3
4
5
7
8
9
6
10
OM-245892 Page 9
5-2. Equipment Connection Diagram - Dual Feeder
1 Welding Power Source
2 Contactor Control/Power Cord
3 Positive (+) Weld Cable
4 Negative (−) Weld Cable
5 Workpiece
6 Welding Gun
7 Wire Feeder
8 Gas Hose
9 Gas Cylinder and Regulator
(Customer Supplied)
. Shielding gas pressure not to
exceed 100 PSI (689 kPa).
10 Coolant Hoses - Water−
cooled Guns Only
245240-A
1
2
3
4
5
6
7
8
9
10
OM-245892 Page 10
5-3. 14-Pin Plug Information For Connecting Wire Feeder To Power Source
Pin* Pin Information
1 Motor 0 to +24 volts DC with respect to pin 2
2 Motor Common
3 +5 volts DC tachometer power
4 Tachometer ref
5 Tachometer signal
6 Trigger
7 Trigger
8 Wire speed ref. +5 volts DC
9 Wire speed com
10 Wire speed 0 to +5 volts DC with respect to pin 9
11 Gun sensing resistor with respect to pin 9
12 Not used.
13 Not used.
14 Not used.
*The remaining pins are not used.
5-4. Opening Top Cover Of XR-AlumaPro Plus Gun
1 Top Cover
Squeeze sides of cover and lift up
as shown.
To close cover, pivot cover closed
on gun, and push cover down until
cover locks tight.
Ref. 804544-B
1
OM-245892 Page 11
! Welding wire is electrically live when
gun trigger is used to jog wire.
Refer to wire feeder manual for instructions on
feeding wire through feeder.
5-5. Threading Welding Wire Through Gun
Ref. 804544-B / 804545-B
Tools Needed:
Lay gun cable out straight. Press Jog switch until about 6
in. (152 mm) of wire is sticking out end of contact tip.
Cut off wire. Close and
latch wire feeder door.
. Turn OFF coolant supply before threading wire
through gun.
For XR-AlumaPro Plus Gun:
. Verify pressure adjustment
on handle matches the wire
type. See Section 6-2.
OM-245892 Page 12
SECTION 6 − OPERATION
6-1. Gun Controls
1 Trigger
Press trigger to energize welding
power source contactor (if
applicable),
start shielding gas flow,
and begin wire feed.
Controls at the wire feeder can be set
to provide timed shielding gas
preflow and postflow when trigger is
pressed and released. When this
feature is turned Off, no preflow or
postflow is provided for the welding
operation.
2 Gun Wire Speed Control
Use control to fine adjust wire feed
speed set at the wire feeder. Gun
Wire Speed Control has 3-3/4 turns
of adjustment from minimum to maxi-
mum.
Rotate control clockwise to increase
wire speed and counterclockwise to
decrease wire speed.
. Speed control can be rotated
more than 3-3/4 turns in both di-
rections without being damaged.
1
2
Ref. 804545-B
6-2. Gun Pressure Roll Tension Setting
. Aluminum series specific -
Pressure roll tension setting
ensures smooth wire feeding
action.
. Gun Pressure Roll Tension is
factory set to 4XXX.
1 Pressure Roll Adjustment
Screw
Wire tension should be set to 4XXX
for 4000 series aluminum wire.
Rotate Pressure Roll Adjustment
Screw fully counterclockwise until
indicator line on adjustment knob
lines up with indicator line on handle
in the 4XXX position.
Wire tension should be set to 5XXX
for 5000 series aluminum and stain-
less wire.
Rotate Pressure Roll Adjustment
Screw fully clockwise until indicator
line on adjustment knob lines up
with indicator line on handle in the
5XXX position.
. Small diameter (.035) 5000
series wire may run better on
the 4XXXX setting.
1
Ref. 804545-B
Tools Needed:
OM-245892 Page 13
6-3. Shielding Gas
Ref. 151666-F / 804545-B
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.
3
1
2
6-4. Coolant Supply For Water-Cooled Models Only
Ref. 150755-A
. Do not loosen head tube with
cooler running.
1 Coolant Supply
2 Coolant “In”
3 Coolant “Out”
See table below for coolant
guidelines.
Turn On coolant supply before
welding.
Turn Off coolant supply when
finished welding.
1
MILLER Aluminum Protecting
Coolant No. 043 809*;
Distilled Or Deionized Water OK
Above 32° F (0° C)
GMAW Or Where Coolant
Contacts Aluminum Parts Or
Where HF* Not Used
Application
*MILLER coolants protect to -37° F (-38°C) and resist algae growth.
Coolant
3
2
Requirement of Coolant Supply
Water-Cooled Models Only
Minimum flow rate: 0.13 G/min (0.5 L/min)
Minimum inlet pressure: 40 psi (276 kPa)
Maximum inlet pressure: 70 psi (483 kPa)
Minimum cooling power: 1000 Watt (3410 BTU/hr)
OM-245892 Page 14
6-5. Gun Drive Assembly Maintenance For An XR-AlumaPro Plus Gun
Ref. 804544-B / 805194-A
Tools Needed:
3
1
7/64, 1/16 in.
2
3/8 in.
1 Lever Arm
Using lever arm open pressure roll
with bearing as shown. Push for-
ward to lock in place.
Retract wire onto spool.
2 Drive Roll
Use wire brush to clean drive roll.
Install drive roll with hex opening
down toward shaft hex, and secure
with screw.
3 Pressure Roll
Thread welding wire through gun.
Engage feeder drive rolls. Press jog
switch until wire is sticking out end
of contact tip.
. When changing wire size
change feeder drive rolls and
guides to match wire size and
type. See wire feeder owners
manual for details.
Close top cover.
OM-245892 Page 15
6-6. Replacing Head Tube Liner In XR-AlumaPro Plus Guns
Ref. 804544-B
. Turn OFF coolant supply before
removing head tube on
water-cooled gun.
The standard head tube liner
(yellow) will accommodate wire
diameters from 3/64 in.- 1/16 in. wire
size.
When changing wire size, change
control box drive roll, idler and head
tube liner with appropriate sized
liner.
1 Head Tube
2 Head Tube Nut
Loosen head tube nut and remove
head tube from gun.
3 Head Tube Liner
Pull liner out of head tube.
Insert new liner into head tube (install
tapered end first) and reinstall head
tube onto gun.
. A twisting motion may be need-
ed to feed liner thru head tube.
NOTICE − Be sure head tube is
seated and head tube nut is securely
tightened before operating gun. If
head tube nut is not adequately tight-
ened, unwanted arcing may occur
between head tube and gun housing.
1
2
3
Tapered end
6-7. Changing Gun Contact Tip
Ref. 246347-A
2
1
1 Nozzle
Unscrew nozzle.
2 Centerfire Contact Tip
Remove contact tip.
Install new contact tip.
NOTICE − Make sure correct size
contact tip is being used. Incorrect
size may cause arcing inside tip,
poor feedability and poor arc start-
ing characteristics(see Section 9).
. Centerfire contact tips de-
signed for aluminum wire have
AL (Example T-.047AL) as a
designator at the end of the part
number.
Reinstall nozzle.
OM-245892 Page 16
Ref. 246348-A
6-8. Replacing The Gun Liner On XR-AlumaPro Plus Guns
! Turn Off welding power source and
wire feeder.
1 Leather Cover
2 Liner
3 Liner Lock Allen Screw
4 Liner Guide Reducer
5 Wire Guide Cone
6 Wire Collet Guide
7 Power Pin
Lay gun cable out straight.
Remove short leather cover to access liner
assembly.
Loosen liner lock allen screw (located near
back of handle) to remove liner guide re-
ducer from gun.
Remove wire guide cone and wire collet
guide from power pin.
Remove old liner from gun end (see il-
lustration above).
Insert new liner into gun end and continue
feeding liner through cable assembly until
liner is through power pin assembly and is
visible.
Install liner assembly into gun and firmly
tighten (do not over tighten) liner lock allen
screw.
Reinstall wire collet guide at power pin and
tighten onto liner.
Cut liner off flush with wire collet guide. Re-
install wire guide cone.
See Section 5-5 for instructions on re-
threading wire.
6 7
4
3
1
Power Pin End
Gun End
2
2
Remove Old Liner (Item 2) From Gun End
Install New Liner (Item 2) Into Gun End
5
. Refer to instructions below.
. Gently pry open
slots to remove
wire collet guide.
. Cut liner flush with
wire collet guide.
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