Miller XR-ALUMAPRO PLUS Owner's manual

Brand: Miller

Model: XR-ALUMAPRO PLUS

Category: Welding System

Type: Owner's manual

This manual is also suitable for

MK380080T

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.

’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

contact ou des pièces de pistolet.

D S’assurer que tous les couvercles et poignées sont fermemen

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

Amperes

Volts

Alternating

Cur-

rent

Duty Cycle

Wire Feed

Gun

Trigger Hold Off

Run-In

Read Instructions

Water (Coolant)

Input

Circuit Breaker

Trigger

Trigger Hold On

Percent

Load Voltage

Line Connection

Continuous

Spot Welding

Hertz

Output

Increase

Spot Weld Time

Primary Voltage

Rated Current

Fuse

Degree Of

Protection

Jog

Press To Set

Purge

Burnback Time

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

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

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

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.

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.

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.

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.

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

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:

7/64, 1/16 in.

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.

Tapered end

6-7. Changing Gun Contact Tip

Ref. 246347-A

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

Power Pin End

Gun End

Remove Old Liner (Item 2) From Gun End

Install New Liner (Item 2) Into Gun End

. Refer to instructions below.

. Gently pry open

slots to remove

wire collet guide.

. Cut liner flush with

wire collet guide.

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Miller XR-ALUMAPRO PLUS Owner's manual

Brand: Miller

Model: XR-ALUMAPRO PLUS

Category: Welding System

Type: Owner's manual

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