Miller Electric XR W User Manual

XR A And XR WProcessesDescriptionMIG (GMAW) WeldingWire Feeder And Feeder GunOM-1581 137 532Y2007−01™™Visit our website atwww.MillerWelds.comFile: MIG

OM-1581 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles

OM-1581 Page 72-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenanceRisque D’INCENDIE OU D’EXPLO-SION.D Ne

OM-1581 Page 82-5. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Documents

OM-1581 Page 9SECTION 3 − SPECIFICATIONS3-1. Wire Feeder SpecificationsSpecification DescriptionType Of Input Power 115 Volts AC, 3 Amperes At 50/60

OM-1581 Page 10SECTION 4 − INSTALLATIONBe sure that contact tip, liner, and drive rolls are correct for wire size and type. SeeSection 5 to change pa

OM-1581 Page 114-2. Connections With A CV Welding Power Source Having Separate 115 VAC AndContactor Control Receptacles1 Constant Voltage (CV) Weld-i

OM-1581 Page 124-4. Connections With A CC Welding Power Source And A 115 VAC/12 VDC SecondaryContactor1 Constant Current (CC) Weld-ing Power Source2

OM-1581 Page 134-6. Air-Cooled Gun Connections31 Gun Control CableInsert plug into Gun Control recep-tacle, and tighten threaded collar.2 Gas HoseCon

OM-1581 Page 144-7. Water-Cooled Gun Connections1 Gas HoseConnect to Gas fitting on feeder.2 Water HoseConnect to water to gun fitting onfeeder (left

OM-1581 Page 154-8. Air-Cooled Feeder Connections1 Gas Hose Grommet2 10 ft (3 m) Gas Hose3 Rear Of Gas FittingRoute one end of gas hose throughgromme

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-1581 Page 164-9. Water-Cooled Feeder ConnectionsObtain coolant supply.1 Gas Hose Grommet2 10 ft (3 m) Gas Hose3 Rear Of Gas FittingRoute one end o

OM-1581 Page 174-10. Voltage Sensing Lead ConnectionsUnit is factory set for constant volt-age (CV) welding. To set unit forconstant current (CC) wel

OM-1581 Page 184-11. 115 VAC/Contactor Control Plug Information1 Interconnecting Cord2 115 VAC/Contactor ControlPlug PLG5If CC or CC/CV welding power

OM-1581 Page 194-12. Replacing 115 VAC/Contactor Control Plug With Customer-Supplied 5-Pin OrTwistlock Plug1 115 VAC/Contactor ControlPlug PLG52 Cont

OM-1581 Page 204-13. Installing Wire SpoolTurn Off wire feeder and weldingpower source.1 Wire Spool2 Top Cover3 Pressure Roll Assembly4 Gun Contact T

OM-1581 Page 214-14. Threading Welding Wire Through Feeder1 Wire SpoolLoosen wire from spool, cut off bentwire, and pull 6 in (150 mm) of wireoff spo

OM-1581 Page 224-15. Threading Welding Wire Through Gun1 Pressure Roll AssemblyLift arm and open pressure rollassembly.2 Wire ConduitLay wire conduit

OM-1581 Page 234-17. Adjusting Wire Feed Starting Speed12Top Of PC1Ref. 151 772-B / Ref. 142 054-BTo adjust wire feed starting speed,proceed as follo

OM-1581 Page 24SECTION 5 − OPERATION5-1. Front Panel Controls Of Feeder (Air-Cooled Model Shown)1 Voltage/Wire Speed Meter(Optional)2 Voltage/Wire Sp

OM-1581 Page 255-4. Run-In Speed Control1 Run-In Speed ControlUse control to set wire feed speedbefore arc initiation.After arc initiation, wire feed

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbo

OM-1581 Page 265-7. Spot Controls (Optional)1 Spot/Continuous SwitchUse switch to select either an un-timed continuous weld cycle or atimed spot weld

OM-1581 Page 275-10. Flowmeter (Optional)CAUTIONWire feeding system is designed for maximum of 50 psi (345 kPa) gas pressure.• Be sure that regulator

OM-1581 Page 285-12. Gun Controls1 Gun TriggerPress trigger to energize weldingpower source contactor (if applica-ble), start shielding gas flow, and

OM-1581 Page 29SECTION 6 − MAINTENANCE & TROUBLESHOOTING6-1. Routine MaintenanceTurn Off all power before maintaining.3 MonthsORBlow OutOrVacuumI

OM-1581 Page 306-2. Changing Or Cleaning Gun Drive RollTurn Off wire feeder and weldingpower source.1 Top Cover2 Pressure Roll AssemblyCut off wire w

OM-1581 Page 316-3. Changing Feeder Drive Roll And Wire Inlet GuideTurn Off wire feeder and weldingpower source. Lay wire conduit outstraight.Open gu

OM-1581 Page 326-4. Replacing Or Cleaning Gun Drive Roll BearingTurn Off wire feeder and weldingpower source.1 Top Cover2 Pressure Roll Assembly3 Scr

OM-1581 Page 336-6. Changing Gun Contact TipRef. 150 437-A21Remove nozzle1 Nozzle2 FasTipUnscrew FasTip.Install new FasTip.6-7. Removing Diffuser In

OM-1581 Page 346-8. Replacing The LinerY Turn Off welding powersource and wire feeder.1 Drive Roll2 Collet NutLay gun cable out straight. Removedrive

OM-1581 Page 356-9. Replacing Hub AssemblyTurn Off wire feeder and weldingpower source. Remove gun topcover and open pressure rollassembly as shown i

TABLE OF CONTENTSSECTION 5 − OPERATION 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-1581 Page 366-10. Adjusting Hub TensionTurn On welding power source andwire feeder to make thisadjustment.1 Wire Speed ControlAdjust control to wi

OM-1581 Page 376-13. TroubleshootingA. Wire Feeder TroubleTrouble RemedyPressing gun trigger does not energizefeeder. Welding wire is not energized.S

OM-1581 Page 38B. Gun TroubleTrouble RemedyNo weld output; gun/feeder does notwork.Secure 115 VAC input plug in 115 volts ac receptacle (see Section

OM-1581 Page 39SECTION 7 − ELECTRICAL DIAGRAMSFigure 7-1. Circuit Diagram For Wire Feeder156 399-C

OM-1581 Page 40195 712-BFigure 7-2. Circuit Diagram For Gun

OM-1581 Page 41Notes

OM-1581 Page 42SECTION 8 − PARTS LIST123456 7891011121314151617181719 20212223242521262728293031323334353637383942434445464748495051525354555657586059

OM-1581 Page 43DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-1. Main AssemblyQuantity1 089 572 Catch, Link-lock 2. . . . . . . . . . . . . . . . . . .

OM-1581 Page 44DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-1. Main Assembly (Continued)Quantity50 111 152 Skid, Base 2. . . . . . . . . . . . . . . .

OM-1581 Page 45DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-2. Motor & Wire Drive (Fig 8-1 Item 71)Quantity1 115 191 Drive Assembly, Wire (Consistin

OM-1581 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _3/05Y Warning: Protect yourself and others from injury — read and follow these pr

OM-1581 Page 4612345678See Fig 8-1Item 5910121314151617181920212223911PC2PC4. Hardware is common andnot available unless listed.145 127-BFigure 8-3. P

OM-1581 Page 47DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-3. Panel, Front w/Components (Fig 8-1 Item 59)Quantity1 ♦111 569 Meter, Flow 6-60 1. . . .

OM-1581 Page 48Figure 8-4. Exploded View Of Gun*Includes Items 24 & 37. Hardware is common andnot available unless listed.803 706-C38(Fig. 8-5)474

OM-1581 Page 49DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-4. Exploded View Of GunQuantity1 214 745 Cover 1. . . . . . . . . . . . . . . . . . . . .

OM-1581 Page 50DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-4. Exploded View Of Gun (Continued)Quantity25 112 896 Spring, Cprsn .240 Od X .020 Wire X .4

OM-1581 Page 51Ref. 800 434-G. Hardware is common andnot available unless listed.12534678179101711121234131415816Figure 8-5. Head Tube Assembly Of Pis

OM-1581 Page 52SECTION 9 − PARTS LIST INCLUDING CONSUMABLESItem Number1234 5Ref. 803 909-A / 803 932 / 803 933 / 803 9346.0” STRAIGHT(#221 087)6.0” ST

OM-1581 Page 53DescriptionPartNo.ItemNo.Figure 9-1. Consumables FlowchartQuantityTable 9-1. Nozzles1 ♦176238 Nozzle, Spot Flat (Requires Diffuser 2090

OM-1581 Page 54DescriptionPartNo.ItemNo.Figure 9-1. Consumables Flowchart (Continued)QuantityTable 9-5. Value Multi−Turn Contact Tips*2 ♦071 825 .030

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2007−01Your distributor also givesyou ...ServiceYou always get the

OM-1581 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Spark

PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914

OM-1581 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or

OM-1581 Page 41-5. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Documents (

OM-1581 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONsom _3/05Y Avertissement : se protéger et protéger les autres contre le risque