Miller MD311656T Le manuel du propriétaire
- Catégorie
- Système de soudage
- Taper
- Le manuel du propriétaire
Ce manuel convient également à
175 Ampere (Air) Push-Pull Welding Gun
XR Aluma-Pro Lite
(Air-Cooled Gun)
Processes
Description
MIG (GMAW) Welding
OM-254 286D 2013−03
Semi-Automatic, Air-Cooled,
MIG (GMAW) Welding Gun
File: MIG (GMAW)
Visit our website at
www.MillerWelds.com
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. 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 5...............................................................
SECTION 4 − INTRODUCTION 6...............................................................
4-1. Specifications 6........................................................................
4-2. Duty Cycle And Overheating 6...........................................................
SECTION 5 − INSTALLATION 7................................................................
5-1. Connections With A Constant Current (CC), Constant Voltage (CV) Or
Constant Current/Constant Voltage (CC/CV) Welding Power Source 7..........................
5-2. Gun Connections 8.....................................................................
5-3. Threading Welding Wire For XR Aluma-Pro Lite Gun And Millermatic 350P/Millermatic 252 9.......
5-4. Threading Welding Wire For XR Aluma-Pro Lite Gun And Millermatic 350P Aluminum 10...........
5-5. Threading Welding Wire Through XR-Control Feeder 11.......................................
5-6. 10-Pin Plug Information 12................................................................
5-7. Opening Top Cover Of XR Aluma-Pro Lite Gun 12............................................
5-8. Threading Welding Wire Through Gun 13...................................................
SECTION 6 − OPERATION 14...................................................................
6-1. Gun Controls 14........................................................................
6-2. Gun Pressure Roll Tension Setting 14......................................................
6-3. Shielding Gas 15........................................................................
6-4. Gun Drive Assembly Maintenance For An XR Aluma-Pro Lite Gun 15...........................
6-5. Replacing Head Tube Liner In XR Aluma-Pro Lite Gun 16......................................
6-6. Changing Gun Contact Tip 16.............................................................
6-7. Replacing The Gun Liner On XR Aluma-Pro Lite Gun 17......................................
SECTION 7 − MAINTENANCE & TROUBLESHOOTING 18.........................................
7-1. Routine Maintenance 18.................................................................
7-2. Cleaning The Gun Liner On XR Aluma-Pro Lite Gun 19.......................................
7-3. Troubleshooting Table 20.................................................................
SECTION 8 − ELECTRICAL DIAGRAMS 21.......................................................
SECTION 9- PARTS LIST 22....................................................................
SECTION 10- PARTS LIST OF CONSUMABLES 26................................................
WARRANTY
OM-254 286 Page 1
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW
WELDING GUNS − READ BEFORE USING
SR7 (MIG) 2011-10
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 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 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.
WELDING can cause fire or explosion.
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.
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-254 286 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. 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 02269 (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, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.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 02269 (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, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA 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). 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, restrict access for passers−by or conduct individual risk assess-
ment for welders. All welders should use the following procedures in or-
der 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-254 286 Page 3
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES
PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT
UTILISATION
SR7(MIG)_2011−10fre
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.
NOTE − 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 vigi-
lant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées dans le manuel d’utilisation du poste de
soudage. Veuillez lire et respecter toutes ces normes de sé-
curité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
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 Réparer ou remplacer un pistolet ou la gaine d’isolement d’un
câble usée, endommagée ou fissurée.
D Mettre la soudeuse hors tension avant de remplacer un bec con-
tact ou des pièces de pistolet.
D S’assurer que tous les couvercles et poignées sont fermement
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 re-
spiratoire.
D Consulter les fiches toxicologiques (MSDS) et les notices du fab-
ricant de chaque matériel utilisé.
LE SOUDAGE peut causer un incen-
die ou une explosion.
D Ne pas souder à proximité de matériaux inflam-
mables.
D Ne pas effectuer le soudage sur des conte-
neurs 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.
L’ACCUMULATION DE VAPEURS
peut causer des lésions ou la mort.
D Quand on n’utilise pas le gaz comprimé de
protection, fermer le robinet de la bouteille.
D Assurer toujours la ventilation des zones fer-
mées 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.
D Porter un casque de soudage muni d’un filtre
de protection oculaire approprié.
D Porter une protection oculaire et des vête-
ments de protection appropriés.
D Protéger la peau nue en portant des vêtements anti-éclabous-
sures.
OM-254286 Page 4
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 con-
tact 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 pis-
tolet 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
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
2-3. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des
malformations congénitales et, dans certains cas, des
cancers. (Code de santé et de sécurité de Californie, chapitre
25249.5 et suivants)
Ce produit contient des éléments chimiques, dont le plomb,
reconnus par l’État de Californie pour leur caractère
cancérogène ainsi que provoquant des malformations
congénitales ou autres problèmes de procréation. Se laver
les mains après toute manipulation.
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 02269 (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, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.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 02269 (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, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
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. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des 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 induc-
tion. Si le médecin approuve, il est recommandé de suivre les procédu-
res précédentes.
OM-254 286 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
Drive rolls can injure fingers.
Safe32 2012−05
3-2. Miscellaneous Symbols
A
Amperes
V
Volts Output
X
Duty Cycle
U
1
Primary Voltage
U
2
Load Voltage
I
1
Primary Current
I
2
Rated Welding
Current
Notes
OM-254 286 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 Aluma-Pro Lite Gun 175 A at 60% Duty Cycle .035 − 3/64 in
(0.9 − 1.2 mm)
70 − 900 IPM
(1.8 − 23.0 mpm)
2.1 lbs (1.0 kg)
(less cables)
4-2. 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
60% Duty Cycle At 175 Peak Amperage
6 Minutes Welding 4 Minutes Resting
60%dutycycle
Notes
OM-254 286 Page 7
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. Connections With A Constant Current (CC), Constant Voltage (CV) Or
Constant Current/Constant Voltage (CC/CV) Welding Power Source
Ref. 257 513-A / Ref. 257 512-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
9
4
XR-D
5
1
5
3
1
2
6
9
8
7
OM-254 286 Page 8
5-2. Gun Connections
Ref. 257 513-A
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.
5
4
Left Side
1
2
3
OM-254 286 Page 9
5-3. Threading Welding Wire For XR Aluma-Pro Lite Gun And
Millermatic 350P/Millermatic 252
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.
. Millermatic 252 is only a two
drive roll system.
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.
Section 5.3
1
2
3
4
Pressure
Indicator
Scale
218243-A
IMPORTANT!
For Aluminum Push-Pull welding.
Thread hub tension nut loosely
IMPORTANT!
For Aluminum
Push-Pull welding.
1
2
3
4
218244-A
See Section 5-8 for threading welding
wire through XR Aluma-Pro Lite gun.
3/4 in.
Tighten to
1/2 lb.
7
8
35621 4
OM-254 286 Page 10
5-4. Threading Welding Wire For XR Aluma-Pro Lite Gun And
Millermatic 350P Aluminum
1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 Drive Roll
5 Wire Conduit
6 Pressure Adjustment Knob
7 Gun Conduit Cable
8 Jog/Purge Switch
Lay gun cable out straight.
Tools Needed:
6 in.
(150 mm)
. Hold wire tightly to keep
it from unraveling.
Open pressure assembly.
Install proper size drive rolls.
Pull and hold wire; cut off end. Push wire thru inlet guide, along
drive roll groove, and into wire
conduit; continue to hold wire.
Close and tighten pressure
assembly according to Tension
Setting chart, and let go of wire.
Remove gun nozzle and contact tip.
Turn On.
255 204-B / Ref. 242 439-A / 257 466-A / 257 470-A
Wire Size Setting
3−4
1−2
0.035 in.
0.040 in.
3/64 in.
Tension Settings
Press gun trigger or jog switch until wire comes
out of gun. Reinstall contact tip and nozzle.
Close and latch door on power source.
7
35
6
21 4
8
OM-254 286 Page 11
5-5. Threading Welding Wire Through XR-Control Feeder
Section 5.4 / Ref. 805 350-A / 242 517-A
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.
1
3
JOG / PURGE
Pull and hold wire; cut off end.
6 in.
(150 mm)
1 Tension Arm
Open tension arm.
. Hold wire tightly to keep
it from unraveling.
1
Adjusting Tension At Feeder
Thread wire thru inlet guide, along drive roll groove, and
into wire conduit. Close tension arm. Adjust tension as
follows:
1
Wire Size Welding Gun Calibration
3−4
3−4
1−2
0.035 in.
0.040 in.
3/64 in.
Tension Settings
Install proper size drive rolls.
Tools Needed:
2
OM-254 286 Page 12
5-6. 10-Pin Plug Information
10
Pin* Pin Information
E
F
D
J
G
C
I
H
B
A
A Not used
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
5-7. Opening Top Cover Of XR Aluma-Pro Lite 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.
257 516-A / 257 517-A
1
OM-254 286 Page 13
! Welding wire is electrically live when
gun trigger is used to jog wire.
. Refer to Section 5-3 for instructions on feeding
wire through feeder.
5-8. Threading Welding Wire Through Gun
257 518-A / 257 516-A / 257 519-A
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.
For XR Aluma-Pro Lite Gun:
. Verify pressure adjustment
on handle matches the wire
type. See Section 6-2.
JOG / PURGE
OM-254 286 Page 14
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.
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.
257 489-A
1
2
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.
257 516-A / 257 519-A
Tools Needed:
1
OM-254 286 Page 15
6-3. Shielding Gas
257 520-A
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.
1
2
3
6-4. Gun Drive Assembly Maintenance For An XR Aluma-Pro Lite Gun
257 523-A
Tools Needed:
3
7/64, 1/16 in.
2
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 sticking
out end of contact tip.
. When changing wire size you
should change the drive rolls in
the XR control box or Millermatic.
See XR or Millermatic Owner’s
Manual for details.
Close top cover.
1
OM-254 286 Page 16
6-5. Replacing Head Tube Liner In XR Aluma-Pro Lite Gun
257 474-A
The standard head tube liner
(yellow) will accommodate 3/64 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 and
reinstall head tube onto gun.
. A twisting motion may be
needed 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
tightened, unwanted arcing may
occur between head tube and gun
housing.
1
2
3
6-6. Changing Gun Contact Tip
257 478-A
Remove nozzle
1 Nozzle
2 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 starting
characteristics(see Section 7-3).
Reinstall nozzle.
2
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Miller MD311656T Le manuel du propriétaire
- Catégorie
- Système de soudage
- Taper
- Le manuel du propriétaire
- Ce manuel convient également à
dans d''autres langues
- English: Miller MD311656T Owner's manual
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