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OM-1589 163 473F
June 1999
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Description
Wire Feeder And Feeder Gun
XR-M Wire Feeder
XR-M Air- And Water-Cooled Guns
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 - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . .
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TABLE OF CONTENTS SECTION 8 − SYSTEM SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 8-1. System Setup Display Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SECTION 9 − STANDARD PULSE WELDING PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 9-1. Program 1 − Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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’s Name: Miller Electric Mfg. Co. Manufacturer’s Address: 1635 W. Spencer Street Appleton, WI 54914 USA Declares that the product: XR-M conforms to the following Directives and Standards: Directives Low Voltage Directive: 73/23/EEC Electromagnetic Compatibility (EMC) Directive: 89/336/EEC Machinery Directives: 89/392/EEC, 91/368
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body. years of resea
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SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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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. AB C B.. Drive rolls can injure fingers 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 wo
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2-2. Manufacturer’s Rating Label for CE Products For label location see Section 3-4. S/N: U 24 V 1 50/60 Hz 1 = = IP 23 I 3.0 A 1 U 100 V I = 400 A X 100 % 2 2 = MILLER ELECTRIC MFG. CO., APPLETON, WI USA 178 794-A 2-3. Symbols And Definitions Some symbols are found only on CE products. NOTE Output Alternating Current Amperes Volts V A Cold Jog (Inch) To- Degree Of Duty Cycle Hertz wards Workpiece X IP Protection Hz Purge Parameter Select Trigger Line Connection Increase Read Instructions Trigg
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SECTION 3 − INSTALLATION 3-1. Specifications Type of Input Welding Power Wire Feed Wire Diameter Welding IP Overall Weight Power Source Type Speed Range Range Circuit Rating Rating Dimensions Constant Voltage (CV) Length: 21-1/4 in .030 To 1/16 in 100 Volts, 400 DC For GMAW Or Net: 48 lb (540 mm) 24 Volts AC (0.8 To 1.6 mm) Amperes, Constant Voltage(CV) / 70 To 875 ipm (21.8 kg) Width: 9-1/2 in Single-Phase 100% Duty Constant Current (CC) DC (1.8 To 22.2 IP 23 Max Spool (241 mm) 3 Amperes Cycle
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3-3. Typical Water-Cooled System Connections 1 300/400 Ampere Model 1 CC/CV Inverter Welding Power Source Use settings shown for both pulse MIG welding and MIG welding. 2 450 Ampere Model CV Inverter Welding Power Source System can be set up with a variety of conventional Constant Voltage (CV) welding power sources. 3 14-Pin Plug And Interconnecting Cord 4 Positive (+) Weld Cable 5 Negative (−) Weld Cable Select and prepare weld cables ac- cording to welding power source Owner’s Manual. 6 Work
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3-4. Rear Panel Connections 1 Rating Label Location 2 Coolant Supply Hose Route supply hose and connect to 1 rear of Water To Gun fitting in feeder. 3 Weld Cable If using conventional welding power source, route through reed relay in feeder. Connect to power block. 4 Coolant Return Hose Route return hose and connect to rear of Weld/Water From Gun fitting or optional flow switch in feeder. 5 Gas Hose 6 14-Pin Plug 6 52 4 3 Tools Needed: 9/16, 5/8, 11/16 in Ref. 800 689 3-5. 14-Pin Plug Informatio
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3-6. Internal Connections for Water-Cooled Gun 1 Wire Conduit 2 Thumbscrew 3 Wire Conduit Block Loosen thumbscrew and insert conduit into block. Tighten thumb- screw. Tighten strain relief. 4 Power Block Weld Cable Connection 5 Weld/Water From Gun Fitting 7 If using a recirculating cool- ant system, make connec- tions directly to gun hose 21 connections at wire feeder. Maintain a minimum 1 qt/min flow rate to prevent damage to gun parts. 6 Water To Gun Fitting 7 Optional Water Flow Switch Fitt
