Miller XR-ALUMAPRO CE Owner's manual

Brand: Miller

Model: XR-ALUMAPRO CE

Category: Welding System

Type: Owner's manual

This manual is also suitable for

MB090002T

250 Ampere (Air) Push-Pull Welding Gun

XR - AlumaPro

(Air And Water-Cooled Guns)

Processes

Description

MIG (GMAW) Welding

OM-248 984A

2011−01

Semi-Automatic, Air/Water-

Cooled, MIG (GMAW) Welding

Gun

™

File: MIG (GMAW)

Visit our website at

www.MillerWelds.com

400 Ampere (Water) Push-Pull Welding Gun

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. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service 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_Thank 2009−09

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. EMF Information 2......................................................................

SECTION 2 − DEFINITIONS 3...................................................................

2-1. WEEE Label (For Products Sold Within The EU) 3...........................................

2-2. Symbols And Definitions 3...............................................................

SECTION 3 − INTRODUCTION 4.................................................................

3-1. Important Information Regarding CE Products (Sold Within The EU) 4...........................

3-2. Specifications 4........................................................................

3-3. Duty Cycle And Overheating 4............................................................

SECTION 4 − INSTALLATION 5..................................................................

4-1. Connections With A Constant Current (CC), Constant Voltage (CV) Or Constant Current/Constant

Voltage (CC/CV) Welding Power Source Having A 14-Socket Receptacle 5......................

4-2. Air-Cooled Gun Connections 6............................................................

4-3. Water-Cooled Gun Connections 7.........................................................

4-4. Millermatic 350P Water Cooled Gun Connections 8..........................................

4-5. Threading Welding Wire For AlumaPro Gun And Millermatic 350P 9.............................

4-6. Threading Welding Wire Through XR-Control Feeder 10.......................................

4-7. Adjusting Tension At Feeder 11............................................................

4-8. 10-Pin Plug Information 12................................................................

4-9. Opening Top Cover Of XR-AlumaPro Gun 12.................................................

4-10. Threading Welding Wire Through Gun 13....................................................

SECTION 5 − OPERATION 14....................................................................

5-1. Gun Controls 14.........................................................................

5-2. Gun Pressure Roll Tension Setting 14.......................................................

5-3. Shielding Gas 15........................................................................

5-4. Coolant Supply For Water-Cooled Models Only 15............................................

5-5. Gun Drive Assembly Maintenance For An XR-AlumaPro Gun 16................................

5-6. Replacing Head Tube Liner In XR-AlumaPro Guns 17.........................................

5-7. Changing Gun Contact Tip 17.............................................................

5-8. Replacing The Gun Liner On XR-AlumaPro Guns 18..........................................

SECTION 6 − MAINTENANCE & TROUBLESHOOTING 19...........................................

6-1. Routine Maintenance For Aluminum Push/Pull Guns 19........................................

6-2. Cleaning The Gun Liner On XR-AlumaPro Guns 20...........................................

6-3. Troubleshooting Table 21.................................................................

SECTION 7 − ELECTRICAL DIAGRAMS 22........................................................

SECTION 8 − PARTS LIST 24.....................................................................

SECTION 9 − PARTS LIST INCLUDING CONSUMABLES 29.........................................

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A ALUMAPRO 300805, 300806, 300807

XRW ALUMAPRO 300003, 300004, 300265

Council Directives:

• 2006/95/EC Low Voltage

Standards:

• IEC 609741:2005 Arc welding equipment – Part 1: Welding power sources

• IEC 609747:2005 Arc welding equipment – Part 7: Torches

• EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding,

arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic

fields (0 Hz – 300Hz)

US Signatory:

December 16, 2010

_____________________________________ ___________________________________________

David A. Werba

Date of Declaration

MANAGER, PRODUCT DESIGN COMPLIANCE

248168A

OM-248 984 Page 1

SECTION 1 −SAFETY PRECAUTIONS FOR GMAW

WELDING GUNS − READ BEFORE USING

SR7 (MIG) 2010−03

Protect yourself and others from injury — read and follow these precautions.

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 unit.

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 Repair or replace worn, damaged, or cracked gun or cable insula-

tion.

D Turn off welding power source before changing contact tip or gun

parts.

D Keep all covers and handle securely in place.

D Keep your head out of the fumes.

D Ventilate area, or use breathing device.

D Read Material Safety Data Sheets (MSDSs)

and manufacturer’s instructions for material

used.

FUMES AND GASES can be hazardous.

D Do not weld near flammable material.

D Do not weld on closed containers.

D Watch for fire; keep extinguisher nearby.

WELDING can cause fire or explosion.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use ap-

proved air-supplied respirator.

MOVING PARTS can injure.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

D Wear welding helmet with correct shade of fil-

ter.

D Wear correct eye and body protection.

D Cover exposed skin with spatter-resistant

clothing.

ARC RAYS can burn eyes and skin.

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.

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 maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local

codes.

OM-248 984 Page 2

1-3. Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases

which contain chemicals known to the State of California to

cause birth defects and, in some cases, cancer. (California

Health & Safety Code Section 25249.5 et seq.)

This product contains chemicals, including lead, known to

the state of California to cause cancer, birth defects, or other

reproductive harm. Wash hands after use.

1-4. EMF Information

Electric current flowing through any conductor causes localized electric

and magnetic fields (EMF). Welding current creates an EMF field

around the welding circuit and welding equipment. EMF fields may inter-

fere with some medical implants, e.g. pacemakers. Protective meas-

ures for persons wearing medical implants have to be taken. For ex-

ample, access restrictions for passers−by or individual risk assessment

for welders. All welders should use the following procedures 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-248 984 Page 3

SECTION 2 − DEFINITIONS

2-1. WEEE Label (For Products Sold Within The EU)

Do not discard product (where ap-

plicable) with general waste.

Reuse or recycle Waste Electrical

and Electronic Equipment (WEEE)

by disposing at a designated collec-

tion facility.

Contact your local recycling office

or your local distributor for further

information.

2-2. Symbols And Definitions

Amperes

Volts Alternating Current

Duty Cycle

Degree Of

Protection

Hertz Circuit Breaker Wire Feed

Jog Output Trigger Gun

Press To Set Increase Trigger Hold On Trigger Hold Off

Purge Spot Weld Time Percent Run-In

Burnback Time

Primary Voltage

Load Voltage Read Instructions

Primary Current

Rated Current Line Connection

Water (Coolant) In-

put

Water (Coolant)

Output

Fuse

Continuous

Spot Welding

OM-248 984 Page 4

SECTION 3 − INTRODUCTION

3-1. Important Information Regarding CE Products (Sold Within The EU)

! 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.

3-2. Specifications

Model Welding Output Range Electrode

Wire Diameter

Capacity

Wire Feed

Speed Range

Net Weight

(Torch Only)

XR-AlumaPro Gun

(Air Cooled)

250 A at 60% Duty Cycle

with 15, 25 or 35 ft

(4.6 or 7.6 m) gun

.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)

XR-AlumaPro Gun

(Water Cooled)

400 A at 100% Duty Cycle

with 15, 25 or 35 ft

(4.6 or 7.6 m) gun

.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.

3-3. 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

Continuous Welding

Air-Cooled Models

Water-Cooled Models

Continuous Welding

60% Duty Cycle At 250 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns

100% Duty Cycle At 400 Peak Amperage Using 100% Argon Gas w/15, 25 Or 35 Foot Guns

OM-248 984 Page 5

SECTION 4 − 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.

4-1. Connections With A Constant Current (CC), Constant Voltage (CV) Or Constant

Current/Constant Voltage (CC/CV) Welding Power Source Having A 14-Socket Re-

ceptacle

Ref. 804 653-A / 805 349-A

1 CC, CV Or CC/CV Welding Power

Source

2 24 VAC/Contactor Control 14-Pin

Plug

3 Negative (−) Weld Cable

4 Workpiece

5 Welding Gun

6 Wire Feeder

7 24 VAC/Contactor Control Cord

8 Positive (+) Weld Cable

9 Gas Cylinder

. Shielding gas pressure not to exceed

100 psi (689 kPa).

Millermatic 350P

XR-D

OM-248 984 Page 6

4-2. Air-Cooled Gun Connections

Ref. 245 995-A / 246 218-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.

Left Side

OM-248 984 Page 7

4-3. Water-Cooled Gun Connections

Ref. 245 997-A / 805 353-A / 246 218-A / 151 666-G

. Turn on coolant supply before

welding or gun will be dam-

aged.

1 Gun Control Cable

Insert plug into Gun Control

receptacle, and tighten threaded

collar.

2 Gun Power Pin

3 Gun Securing Knob

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

Connect to Water “Out” fitting on

feeder (left-hand threads).

7 Gun (Coolant) “Out” Hose

Connect to Water “In” fitting on

feeder (left-hand threads)

8 Water Cooler Output

9 Water Cooler Input

10 Feeder (Coolant) Output

11 Feeder (Coolant) Input

Tools Needed:

9/16 in.

Left Side

OM-248 984 Page 8

4-4. Millermatic 350P Water Cooled Gun Connections

Ref. 804 945-A

NOTICE − Turn on coolant supply before

welding or gun will be damaged.

1 Coolant Supply

2 Millermatic 350P

3 Gun Control Cable

Insert plug into gun control receptacle and

tighten threaded collar.

4 Water In Hose

Connect to coolant supply with supplied

coupler and water hose (left-hand threads).

5 Gun Connector

Loosen gun securing knob, and insert gun

connector through Wire opening until it

bottoms against block. Tighten knob. Close

and latch door.

6 Water Out Hose

Connect to coolant supply with supplied

coupler and water hose (left-hand threads).

7 Coolant “In”

8 Coolant “Out”

Tools Needed:

9/16 in.

OM-248 984 Page 9

4-5. Threading Welding Wire For AlumaPro Gun And Millermatic 350P

1 Wire Spool

2 Welding Wire

3 Inlet Wire Guide

4 Drive Roll

5 Intermediate Wire Guide

6 Outlet Wire Guide

7 Pressure Adjustment Knob

8 Gun Conduit Cable

Lay gun cable out straight.

Tools Needed:

6 in.

(150 mm)

. Hold wire tightly to keep it

from unraveling.

Open pressure assembly.

Pull and hold wire; cut off end.

Push wire thru guides into gun;

continue to hold wire.

Close and tighten pressure

assembly, and let go of wire.

. Set pressure indicator

scale to 1/2 lb.

Ref. 803 544-A / 218 243-A / 218 244-A / S-0627-A

Pressure

Indicator

Scale

218243-A

IMPORTANT!

For Aluminum Push-Pull welding.

Thread hub tension nut loosely

IMPORTANT!

For Aluminum

Push-Pull welding.

218244-A

35621 4

See Section 4-10 for threading weld-

ing wire through AlumaPro guns.

3/4 in.

Tighten to

1/2 lb.

OM-248 984 Page 10

4-6. Threading Welding Wire Through XR-Control Feeder

Ref. 246 218-A / 805 354

Tools Needed:

1 Cable Assembly

Lay cable assembly out straight.

2 Jog Switch

Push Jog switch up to feed wire through

cable assembly.

3 Torque Switch

. Select proper push feeder torque set-

ting for wire size being used. Use low

torque for .030 in. (0.8mm) wire. Use

high torque for all other wire sizes.

. XR-AlumaFeed torque setting is auto-

matically set internally for wire sizes.

JOG / PURGE

Notes

OM-248 984 Page 11

4-7. Adjusting Tension At Feeder

Ref. 805 350-A / 242 517-A

Tools Needed:

Pull and hold wire; cut off end.

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 unraveling.

Wire Size Welding Gun Calibration

3−4

1−2

0.035 in.

0.040 in.

3/64 in.

1/16 in.

Tension Settings

Install proper size drive rolls.

OM-248 984 Page 12

4-8. 10-Pin Plug Information

Pin* Pin Information

A Electrode sense lead

B Motor Common

G Trigger

C Motor 0 to +24 volts DC with respect to pin B

D Trigger

E Wire speed Ref. +9 volts DC

H Wire speed com

F Wire speed 0 to +9 volts DC with respect to pin H

J Gun sensing resistor with respect to pin H

I Not used

4-9. Opening Top Cover Of XR-AlumaPro 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. 804 544-B

OM-248 984 Page 13

! Welding wire is electrically live when

gun trigger is used to jog wire.

. Refer to Section 4-5 for instructions on feeding

wire through feeder.

4-10. Threading Welding Wire Through Gun

Ref. 804 544-B / 804 545-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 Gun:

. Verify pressure adjustment

on handle matches the wire

type. See Section 5-2.

JOG / PURGE

OM-248 984 Page 14

SECTION 5 − OPERATION

5-1. Gun Controls

1 Trigger

Press trigger to energize welding

power source contactor (if

applicable), start shielding gas flow,

and begin wire feed.

Switches inside 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 on XR-Control. Gun Wire

Speed Control has 3-3/4 turns of ad-

justment from minimum to maximum.

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. 804 545-B

5-2. 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.

Ref. 804 545-B

Tools Needed:

OM-248 984 Page 15

5-3. Shielding Gas

Ref. 151 666-F / 804 545-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

5-1).

Close valve on cylinder when

finished welding.

5-4. Coolant Supply For Water-Cooled Models Only

Ref. 150 755-A

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

OM-248 984 Page 16

5-5. Gun Drive Assembly Maintenance For An XR-AlumaPro Gun

Ref. 804 544-B / 805 194-A

Tools Needed:

7/64, 1/16 in.

3/8 in.

1 Lever Arm

Using lever arm open pressure roll

with bearing as shown.

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.

Close pressure roll assembly and

idler roll (located in XR control box).

Press jog switch until wire is stick-

ing out end of contact tip.

. When changing wire size and

using an XR control box you

should change the control box

drive roll and idler. See XR

owners manual for details.

Close top cover.

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Miller XR-ALUMAPRO CE Owner's manual

Brand: Miller

Model: XR-ALUMAPRO CE

Category: Welding System

Type: Owner's manual

This manual is also suitable for

MB090002T

Download PDF

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Miller XR-ALUMAPRO CE Owner's manual

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Miller XR-ALUMAPRO CE Owner's manual

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