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OM-227 398D
2007 −12
Processes
MIG (GMAW) Welding
Description
Semi-Automatic, Air/Water-
Cooled, MIG (GMAW) Welding
Gun
™
XR - Aluma-Pro
(Air And Water-Cooled Guns)
300 Ampere (Air) Push-Pull Welding Gun
400 Ampere (Water) Push-Pull Welding Gun
File: MIG (GMAW)
Visit our website at
www.MillerWelds.com
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From Miller to You 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 bu
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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. EMF Information . . . . . . . . . . . . . . . . . . . . . . .
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Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer: European Contact: Miller Electric Mg. Co. Mr. Danilo Fedolfi, 1635 W. Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r.l. Phone: (920) 734-9821 Via Privata Iseo 6/E 20098 San Giuliano Milanese, Italy Phone: 39(02)98290-1 Fax: 39(02)98290203 European Contact Signature: Declares that the produ
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SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING SR7_2007 −04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. 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
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1-3. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them, or using a Electric And Magnetic Fields cable cover. Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator. magnetic fields. There has been and still is some concern about such 3. Do not coil or drape cables around your body. fields. However, after examining more than 500 studies sp
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SECTION 2 − DEFINITIONS 2-1. Warning Label Definitions A. Warning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. AB C C. Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects clear. 1 Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric shock by insulating yourself 1 1.1 1.2 1.3 from work
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2-2. Manufacturer’s Rating Label For CE Products Only 229 109-A 2-3. 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. 2-4. Symbols And Definitions Some symbols are found only on CE products. Amperes Volts Alternating Current Duty Cyc
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SECTION 3 − INTRODUCTION 3-1. Specifications Model Welding Output Range Electrode Wire Feed Net Weight Wire Diameter Speed Range (Torch Only) Capacity XR-Aluma-Pro Gun 300 A at 100% Duty Cycle .030 To 1/16 in 70 To 900 ipm 2.5 lb (1.1 kg) (Air Cooled) with 15, 25 or 35 ft (0.8 To 1.6 mm) (1.8 To 23 mpm) (less cables) (4.6 or 7.6 m) gun aluminum wire XR-Aluma-Pro Gun 400 A at 100% Duty Cycle .030 To 1/16 in 70 To 900 ipm 2.9 lb (1.3 kg) (Water Cooled) with 15, 25 or 35 ft (0.8 To 1.6 mm) (1.8 To
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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 1 CC, CV Or CC/CV Welding Power Source 2 24 VAC/Contactor Control 14-Pin Plug 3 Workpiece 4 Voltage Sensing Lead 1 (Optional) Connect lead to workpiece for CC welding only. 5 Gun
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4-2. XR-Water-Cooled Gun Connections 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 Connector 3 Gun Securing Knob 3 4 Gun Connector Block Loosen gun securing knob, and 2 insert gun connector through Wire opening until it bottoms against block. Tighten knob. Close and latch door. 4 5 Gun (Coolant) “In” Hose Connect to Water “In” fitting on feeder (left-hand threads). 6 Gun (Coolant)
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4-3. Millermatic 350P Water Cooled Gun Connections 8 7 1 2 Ref. 804 945-A 6 5 3 4 Tools Needed: 9/16 in 4 Water In Hose bottoms against block. Tighten knob. Close Turn on coolant supply before welding and latch door. or gun will be damaged. Connect to coolant supply with supplied 6 Water Out Hose 1 Coolant Supply coupler and water hose (left-hand threads). Connect to coolant supply with supplied 2 Millermatic 350P 5 Gun Connector coupler and water hose (left-hand threads). 3 Gun Control Cable
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4-4. Threading Welding Wire For Aluma-Pro 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 7 Pressure Adjustment Knob 8 Gun Conduit Cable Lay gun cable out straight. Tools Needed: 8 1 235 4 6 Hold wire tightly to keep it IMPORTANT! from unraveling. For Aluminum Push−Pull welding. Thread hub tension nut loosely 6 in (150 mm) 218243−A 3/4 in Pull and hold wire; cut off end. Open pressure assembly. IMPORTANT! Tigh
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4-5. Threading Welding Wire Through XR-Control Feeder 1 Cable Assembly Lay cable assembly out straight. 2 Jog Switch Tools Needed: Push Jog switch up to feed wire through 2 cable assembly. 1 Ref. 802 193-A 4-6. Adjusting Tension At Feeder Tools Needed: Hold wire tightly to keep it from unraveling. 6 in (150 mm) Open tension arm. Pull and hold wire; cut off end. Proceed to Section 4-9. Thread wire thru inlet guide, along drive roll groove, and into wire conduit. Close tension arm. Adjust tensi
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4-7. 10-Pin Plug Information Pin* Pin Information 10 A Electrode sense lead B Motor Common G Trigger E F F D J C Motor 0 to +24 volts dc with respect to pin B G G I D Trigger C H H B A 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 4-8. Opening Top Cover Of XR-Aluma-Pro Gun 1 Top Cover Squeeze sides of cover and lift up as shown. To close cover, pivot cover closed on gun, and push cover do
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4-9. Threading Welding Wire Through Gun Refer to Section 4-4 for instructions on feeding wire through feeder. For XR-Aluma-Pro Gun: ! Welding wire is electrically live when gun trigger is used to jog wire. Turn OFF coolant supply before threading wire Lay gun cable out straight. Press Jog switch until about 6 through gun.. in (152 mm) of wire is sticking out end of contact tip. Verify pressure adjustment on handle matches the wire type. See Section 5-2. Cut off wire. Close and latch wire f
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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 1 speed set on XR-Control. Gun Wire Spe
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5-3. Shielding Gas 1 Shielding Gas Cylinder 2 Valve 3 Gun Trigger 2 Open valve on cylinder just before 1 welding. Gun trigger turns weld output and gas flow on and off (see Section 5-1). Close valve on cylinder when finished welding. 3 Ref. 151 666-F / 804 545-B 5-4. Coolant Supply For Water-Cooled Models Only 1 Coolant Supply 2 Coolant “In” 3 Coolant “Out” See table below for coolant 1 guidelines. Turn On coolant supply before 3 welding. Turn Off coolant supply when 2 finished welding. GMAW Or
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5-5. Gun Drive Assembly Maintenance For An XR-Aluma-Pro Gun 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 2 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 siz
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5-6. Replacing Head Tube Liner In XR-Aluma-Pro Guns Turn OFF coolant supply before removing head tube on water-cooled gun. The standard head tube liner will ac- commodate wire diameters from .030-.035 wire size. When changing wire size, change control box drive roll, idler and head tube liner with appropriate sized lin- 3 er. 1 Head Tube 2 Head Tube Nut 2 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
