OM-1500-17 218 022G 2006−06 Processes MIG (GMAW) Welding Description Semi-Automatic, Air-Cooled, MIG (GMAW) Welding Gun ™ XR -A Python 25 Ft. ® 200 Ampere Push-Pull Welding Gun File: MIG (GMAW) Visit our website at www.MillerWelds.
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.
TABLE OF CONTENTS SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. GMAW Gun Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMF INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of Conformity for European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Manufacturer: European Contact: Miller Electric Mg. Co. 1635 W. Spencer St. Appleton, WI 54914 USA Phone: (920) 734-9821 Mr. Danilo Fedolfi, Managing Director ITW Welding Products Italy S.r.l.
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING SR7_8/03 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means NOTE; not safety related. This group of symbols means Warning! Watch Out! Possible ELECTRIC SHOCK and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2.
EMF INFORMATION NOTE Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields − Background Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May 1989): “. . .
SECTION 2 − DEFINITIONS 2-1. Warning Label Definitions A B 1 1.1 2 2.1 3 3.1 4 4.1 5 + C 1.2 2.2 1.3 2.3 3.2 + 3.3 + + 6 S-178 936 A. Warning! Watch Out! There are possible hazards as shown by the symbols. 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.
2-2. Symbols And Definitions Note A IP Some symbols are found only on CE products.
SECTION 3 − INSTALLATION 3-1. Specifications Wire Capacity Aluminum wire - .030 in - 1/16 in (0.8 mm - 1.6 mm) using teflon liner Cored and Hard wire - .030 in - .045 in (0.6 mm - 1.2 mm) using spiral steel liner Wire Speed At rated feeder input voltage - 70-800 Ipm (20.3 mpm) Duty Cycle - 100% (200 Amps peak) All ratings are based from using Argon gas Gun Weight Less leads − 2.5 lbs (1.13 kg) Shipping Weight Approximately 19.29 lbs (8.29 kg) Ref. 803 870-A 3-2.
SECTION 4 − OPERATION 4-1. Controls and Settings 1 Potentiometer The potentiometer is located in the lower end of the handle, providing up to 800 ipm (20.3 mpm) with 3 3/4 turns. 2 3 2 Trigger Trigger Sensitivity Adjustment Screw The amount of trigger level travel can be shortened for quicker response action. 1 A more sensitive trigger lever is produced by reducing the gap between the trigger lever and the micro switch lever.
4-2. Drive Roll Removal/Installation 1 2 3 4 1 Drive Roll Removal Tool P/N 215676 Drive Roll Idler Roll Cam Lever . The gun handles do not need to be removed for access to the drive or idler rolls. Drive Roll Removal/Installation . For insulated drive roll kits see Section 8 Options and Accessories. Pull cam lever away from idler roll. This relieves pressure against the the drive roll. Align drive roll removal tool over the flats of the drive roll as shown.
4-3. Idler Roll Removal/Installation 1 2 3 4 5 Idler Roll Lockwasher Idler Arm Spring Idler Screw . The gun handles do not need to be removed for access to the drive or idler rolls. Idler Roll Removal/Installation Using a slot type screwdriver, loosen idler screw, taking care not to lose lock washer under idler roll. Insert new idler roll and lock washer onto screw, insuring that idler groove is toward top and lock washer is beneath. . Lock washer must be under idler roll or it will not turn freely.
SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. Each Spool Of Wire Clean Nozzle And Check Contact Tip Blow Out Gun Casing and Conduit 3 Months Replace Damaged Or Unreadable Labels Clean And Tighten Weld Terminals Replace Damaged Gas Hose Repair Or Replace Cracked Cables And Cords 5-2. Troubleshooting Guide Y Disconnect power before troubleshooting.
5-3. Troubleshooting Table Y Disconnect power before troubleshooting. Trouble Remedy No wire feed at gun, feeder not operat- Reset circuit breaker in feeder/control box. See feeder/control owner’s manual. ing Check motor or brake solenoid ing. solenoid. Replace micro-switch and test operation. Check micro-switch wires for continuity. No wire feed at gun, feeder operating Reset circuit breaker in feeder/control box and check for short in motor leads. See feeder/control owner’s manual. properly.
SECTION 6 − ELECTRICAL DIAGRAMS 220 166-A Figure 6-1.
30 31 30 OM-1500-17 Page 12 9 25 4 1 18 19 17 3 29 12 21 23 24 32 6 35 28 26 20 27 5 Figure 7-1. XR -A Python 25 Ft.
Item No. Part No. Description Quantity Figure 7-1. XR -A Python 25 Ft. . . . 1 . . . . . . . . . . 220 688 . . Cam Idler Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . 220 689 . . Brazed Rear Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 3 . . . . . . . . . *215 668 . . Trigger Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 1 7 9 2 4 8 6 3 5 803 876-A Figure 7-2. Front Body Assembly Item No. Part No. Description Quantity Figure 7-2. Front Body Assembly . . . 1 . . . . . . . . . . 220 715 . . . 2 . . . . . . . . . . 220 716 . . . 3 . . . . . . . . . . 220 719 . . . 4 . . . . . . . . . . 220 720 . . . 5 . . . . . . . . . . 220 721 . . . 6 . . . . . . . . . . 220 722 . . . . . . . . . . . . . . . . 215 674 . . . 7 . . . . . . . . . *220 717 . . . 8 . . . . . . . . . *220 718 . . . 9 . . . . . . . . . *220 723 . .
3 10 6 8 9 7 2 1 5 4 803 878-B Figure 7-3. Barrel Assembly Item No. Part No. Description Quantity Figure 7-3. Barrel Assembly . . . . . . . . . . . . . . . . 215 687 . . Barrel Assy, Air/Water Cooled 60 Deg (Includes) . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . . . . . . . *206 195 . . . . Diffuser, 1/8 Tip Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . 220 724 . . . . Assy Barrel Bend . . . . . . .
Item No. Part No. Description Quantity Figure 7-3. Barrel Assembly Consumables Flowchart Nozzles ... ... ... ... ... ... ... ... ... ... ... ... 4 4 4 4 4 4 4 4 4 4 4 4 . . . . . . . . ♦176 238 . . . . . . . . ♦176 240 . . . . . . . . ♦176 242 . . . . . . . . . . 199 610 . . . . . . . . . . 199 611 . . . . . . . . . . 199 612 . . . . . . . . . . 199 613 . . . . . . . . . . 199 614 . . . . . . . . . . 199 615 . . . . . . . . . . 199 616 . . . . . . . . . . 199 617 . . . . . . . . . . 198 855 .. .. ..
4 9 5 6 7 8 1 2 3 803 877-B Figure 7-4. Power/Gas Connector Item No. Part No. Description Quantity Figure 7-4. Power/Gas Connector ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 .......... .......... .......... .......... .......... .......... .......... .......... .......... 602 172 220 700 202 513 226 445 193 896 220 729 141 694 137 495 079 974 .. .. .. .. .. .. .. .. .. Set Screw, 10-32 x 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − OPTIONS AND ACCESSORIES Insulated Drive Roll Kits Used to prevent preheating of the wire which may soften it and clog the liner. This picking up of current at the drive rolls rather than at the contact tip is usually not a problem unless using too large of a contact tip or excessively oxidized aluminum wire. Insulated groove drive roll kits include insulated drive roll and idler roll assembly. Wire Size Part Number 0.030 (0.8mm) 215677 0.035 (0.9mm) 215678 0.045 (1.2mm) 215681 0.062 (1.
Effective January 1, 2006 (Equipment with a serial number preface of “LG” or newer) Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co.
