XR Control
Issued January 2003 • Index No. M/1.7
™
Quick
Specs
Push-Pull
Wire Feed System
Heavy Industrial Applications
Processes
Emergency Vehicles
Shipbuilding
Trucks and Trailers
Railcars
Fabrication
MIG (GMAW) Welding
Recreational Vehicles
Tool Boxes
Heat Exchangers
Sign Manufacturers
Rated Output
Input Power 24 VAC, 50/60 or 100 Hz
Wire Speed 70 – 875 IPM (1.8 – 22.2 m/min)
Weight 38 lb (17.2 kg)
The Power of Blue .
®
Trigger hold reduces fatigue by allowing
operator to weld without holding trigger.
Wire jog control allows wire to be
threaded through gun cable without
energizing weld output.
Unique solid-state control permits
XR systems to work with most CC, CV,
or CC/CV, DC welding power sources.
Adjustable gun barrel allows operator to
easily vary contact tip to nozzle position.
Digital display indicates wire feed
speed or weld voltage.
Patented quick-change, single-turn
contact tip provides excellent
performance and ease of replacement.
Push-pull design feeder motor provides
continuous push force to the wire while
the gun motor controls wire feed speed
at the arc, together providing accurate
and positive wire feed speed.
XR-Pistol Gun
Master/gun wire feed speed control
improves resolution by limiting speed
range available at the gun, making it
easier to fine-tune arc conditions.
Unique arc starting control can be
adjusted to tune arc starting, reducing
wire stubbing or arc flaring which can
result in burnbacks to the contact tip.
Gear-driven, smooth groove drive
rolls reduce deformation of the wire
and provide positive feeding
performance by having both rolls
driving the wire, helping to reduce
burnbacks and enhancing arc starts.
Replaceable feed cable liner reduces
parts cost and service time by allowing a
simple means of removing and replacing
liner and not the complete feed cable.
Easy access to drive assembly and
removable head tube reduces service
time by allowing a simple means of
changing drive rolls and head tube or
performing routine maintenance without
disassembly of gun.
Air: 250 A at 100% Duty Cycle
Water: 400 A at 100% Duty Cycle
Control shown with
optional voltage control and gas flowmeter.
A Complete System Consists of the Following:
Control
Gun
Fastip™/Drive Roll Kit
Select from either an XR-Pistol gun or
an XR-Edge gooseneck-style gun. Both
feature a quick-connect to the Control and
are available in air- and water-cooled
versions with 15 or 30 ft cable lengths.
XR-Edge gun also available in 50 ft.
The XR-Pistol and XR-Edge guns have
a patented gas delivery that reduces
weld cleanup and repair by improving
gas shielding coverage through reduction
of atmospheric contamination.
(Kits must be ordered separately and consist
of gun drive rolls, control box drive rolls and five
FasTip ™ contact tips.)
See back page for more information on 3-step process
used to order and assemble a complete system.
XR-Edge Gun
The XR-Edge gun also features a toolless
360 degree rotating head tube that
reduces operator fatigue by providing
a simple means of positioning gun
comfortably for various welding positions.
Wire feeder is warranted for 3 years, parts and labor.
Guns are warranted for 1 year.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
XR Control Specifications
(Use with CC/CV,
DC Power Sources.)
(Subject to change without notice.)
Input Power
Wire Speed
Maximum Spool Size Capacity
Dimensions
Net Weight
24 VAC, 50/60 or 100 Hz
70 – 875 IPM (1.8 – 22.2 m/min)
12 in (305 mm)
H: 16 in (406 mm)
W: 9-1/4 in (235 mm)
D: 21-1/4 in (540 mm)
38 lb (17.2 kg)
®
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
Conforms to European standards.
NRTL/C
XR Control Panel
17
13
2
18
3
1
4
5
14
6
19
7
8
9
10
15
16
11
Side Panel
12
Front Panel
2
1. Gas Flowmeter*
2. Voltage/Wire Speed Meter
3. Voltage/Wire Speed Switch
4. Voltage Control*
5. Wire Speed Control
6. Schedule A Indicator LED*
7. Press To Set Push Button*
8. Schedule B Indicator LED*
9. Wire Speed B Control*
10. Remote Volts B Control*
11. Wire Jog/Gas Purge Switch
12. Trigger Hold Switch
13. Run-In Speed Control
14. Burnback Time Control*
15. Continuous/Spot Time
Control*
16. Spot Time Range Switch*
17. Fuse F1
18. Circuit Breaker CB1
19. Motor Torque Switch
*Optional
XR Control Genuine Miller Options
*Factory option available only in XR Control packages
— see Ordering Information on page 8.
Voltage Control*
#194 027 Field
Allows voltage
adjustment at the
current XR Control
when used with
Miller electrically
controlled, constant-voltage DC power
sources that have a 14-pin receptacle.
Dual Schedule
Control* #193 276
Field
Allows two different
welding conditions
(voltage and wire
feed speed) to be
used on the same
wire. This is ideal
when different heat settings are required or
when the need arises to change conditions
while welding, i.e. different material
thickness, out of position welding, etc. Is
also ideal for use as a start control or crater
fill control.
Note: The Digital Display is required to use the Dual
Schedule. Only for use with Miller CV or CC/CV power
sources. Dual Schedule Switch required.
Digital Display
V/WFS*
#193 274 Field
For XR Control prior
to serial #LC122752.
Note : Voltage Sense Lead (#209 867) required for
voltage display when used with non-solid-state Miller
and competitive power sources.
Allows wire feed speed to be preset and
displayed. Will also monitor voltage while
welding. If used with current manufactured
Miller CV or CC/CV power sources
(excluding CPs) and the optional voltage
control or dual schedule control is used,
the arc voltage can also be preset on the
digital display. Includes back-lit LCD digital
display that is easy to read in virtually any
lighting condition. A selector switch allows
the display to switch between wire feed
speed and voltage.
Dual Schedule Switch
DSS-30 #193 271 Field
For 15 ft (4.6 m) and 30 ft (9 m) guns
DSS-50 #193 272 Field
For 50 ft (15.2 m) gun
Required to operate the dual schedule
control. A two position slide switch that
can be positioned at the XR-Edge gun to
remotely select schedule A or B conditions.
Gas Flowmeter*
#193 278 Field
#197 793 Field w/CE
Monitors and adjust gas flow
at the XR Control.
Note: Gas pressure must be controlled
at the primary gas supply with the
use of a regulator.
Spot Weld/Burnback
Control #193 279 Field
Provides up to 5 seconds
of spot weld time and
0 (zero) to 0.25 seconds
of burnback time.
Water Flow Shutdown Switch
#194 039 Field
For use with water-cooled guns only.
Protects the water-cooled gun from
overheating if water is not present or water
stops flowing to the gun.
XR Control Genuine Miller Accessories
Optima™ MIG (GMAW)
Pulse Control #043 389
For Invision and XMT 304
CC/CV. A multipurpose,
microprocessor-based
pulse control for synergic
MIG (wire welding or
GMAW), manual MIG
pulsing or standard MIG
welding. Use this control with all above
power sources and any Miller wire feeder.
Includes 25 ft (7.6 m) cord with 14-pin plug.
PSA-2 Control #141 604
Required when using the
XR Control with power
sources having only
115 VAC available.
Mounts at power source
and includes a 10 ft (3 m)
115 VAC cord and
contactor cord with Hubbell connectors.
A simple modification in the PSA-2 control
also allows it to be used with competitive
constant voltage power sources requiring
a contact closure for contactor control.
The PSA-2 includes a 14-pin receptacle
for direct connection of the standard
interconnecting cord and optional extension
cords. Bracket included for side mounting
to the power source.
Water Coolant Systems
Coolmate V3
Coolmate 3
Coolmate 4
Note: When using the PSA-2 control, the optional
Remote Voltage Control is not functional.
Extension Cords
#122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (22.9 m)
Provides 14-pin, 24 VAC, contactor and
voltage control. Can be added to the
standard 10 ft (3 m) feeder cord to extend
feeder farther from power source.
Coolmate™ 3
Coolmate™ 3
Coolmate™ V3
Coolmate™ 4
#043 007 115 VAC
#043 008 230 VAC
#043 009 115 VAC
#042 288 115 VAC
For use with water-cooled guns. Refer to
Lit. Index No. AY/7.2 for additional coolant
system information.
Coolant #043 809
Sold in cases of four 1-gallon recyclable
plastic bottles.
3
XR-Edge Gun
(Note: Air-cooled gun shown.)
4
3
2
1
XR-Edge Gun Specifications
Welding Output Range
XR-A Edge Gun
Air: 250 A at 100% Duty Cycle
XR-W Edge Gun
Water: 400 A at 100% Duty Cycle
®
6
Head Tube Liner
Liner O-Ring
Head Tube O-Ring
Head Tube (Air-cooled)
Lock Nut
7
8
#212 523
#164 485
#191 191
#191 180
#185 111
9
10
6. Insulator
#185 097
7. Gas Diffuser
#209 875
8. Contact Tip
(See chart on pg 5)
#185 102
9. Adapter Jam Nut
10. Nozzle
(See below)
(Subject to change without notice.)
Model
A=Air-Cooled W=Water-Cooled
1.
2.
3.
4.
5.
5
Electrode Wire
Diameter Capacity
Wire Speed
Dimensions
.030 –.062 in (0.8 –1.6 mm)
aluminum wire
70–875 IPM
(1.8–22.2 m/min)
H: 5 in (127 mm)
W: 2-1/2 in (64 mm)
D: 17 in (432 mm)
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
Net
Weight
2.5 lb
(1.1 kg)
Conforms to European standards.
NRTL/C
Note: See back page for ordering XR-Edge FasTip™/Drive Roll Kits (one required).
XR-Edge and XR-Pistol Nozzles
#197 728
5/8 in (16 mm)
orifice (Standard)
4
#193 790
1/2 in (13 mm)
orifice
(Order from Miller Service Parts.)
#009 925
Spot outside
corner
#000 443
Spot inside
corner
#000 442
Spot flat 15/16 in
(24 mm) orifice
#004 466
Spot flat 1-3/8 in
(35 mm) orifice
Note: Nozzle adapter
kit #193 794 required.
Note: Nozzle adapter
kit #193 794 required.
Note: Nozzle adapter
kit #193 794 required.
Note: Nozzle adapter kit
#193 794 required.
XR-Pistol Gun
(Note: Air-cooled gun shown.)
1
1.
2.
3.
4.
5.
XR-Pistol Gun Specifications
Model
Welding Output Range
XR-A Gun
Air: 250 A at 100% Duty Cycle
XR-W Gun
Water: 400 A at 100% Duty Cycle
A=Air-Cooled W=Water-Cooled
®
2 3
4
Head Tube Liner
O-Ring .176 ID
O-Ring .614 ID
Head Tube (Air-cooled)
Insulator
#212 156
#134 800
#164 485
#210 511
#185 097
5
6.
7.
8.
9.
6
7
8
Gas Diffuser
Jam Nut (Air-cooled)
Contact Tip
Nozzle
9
#209 875
#185 102
(See chart below)
(See pg 4)
(Subject to change without notice.)
Electrode Wire
Diameter Capacity
Wire Speed
Dimensions
.030 –.062 in (0.8 –1.6 mm)
aluminum wire
70–875 IPM
(1.8–22.2 m/min)
H: 7-3/8 in (187 mm)
W: 1-7/8 in (48 mm)
D: 10-5/8 in (270 mm)
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
Net
Weight
2.4 lb (1.1 kg)
2.9 lb (1.3 kg)
Conforms to European standards.
NRTL/C
Note: See back page for ordering XR-Pistol FasTip™/Drive Roll Kits (one required).
XR-Edge and XR-Pistol Replacement Consumables (Air-Cooled Only) (Order from Miller Service Parts.)
Wire Size
FasTip Contact Tip
Standard XR-Edge
Drive Rolls
Optional Isolated
XR-Edge Drive Rolls
XR-Pistol
Drive Rolls
XR-Pistol All-Wire
Dual Groove Drive Rolls
.030 in (0.8 mm)
.041 in ID #206 177
#194 114
#198 434
#183 357
#136 135
.035 in (0.9 mm)
.047 in ID #206 178
#194 115
#198 435
#183 357
#136 135
.040 in (1.0 mm)
.053 in ID #206 179
#196 302
#198 436
#183 357
#136 135
.047 in (1.2 mm)
.061 in ID #206 180
#194 116
#198 437
#183 358
#136 135
.062 in (1.6 mm)
.071 in ID #206 181
#194 117
#198 438
#183 358
#136 135
Head Tube Liners
Part #
Cable Liners
Part #
XR Control Drive Rolls
Part #
XR-Pistol
#212 156
15 ft (4.6 m) or 30 ft (9.1 ft)
#191 065
.030 in (0.8 mm)
#194 118
XR-Edge
#212 523
50 ft (15.2 m)
#191 066
.035 in (0.9 mm)
#194 118
.040 in (1.0 mm)
#196 301
.047 in (1.2 mm)
#194 119
.062 in (1.6 mm)
#195 591
Note: These are replacement consumables. See back page for initial setup kits.
5
XR Gun Genuine Miller Accessories
Cable Cover
#118 677 15 ft #118 678 30 ft
50 ft cable cover is not available. Protects
gun hose and cable assembly from wear
and abrasion. Features a full length zipper.
Hardwire Liner Kits for Steel and Stainless
#198 377 For 15 or 30 ft guns
For XR-Pistol and XR-Edge guns. Kits consist
of gun head tube liner and feed cable liner.
Recommend using .030 – .045 in mild steel,
flux cored, or stainless steel electrode wire.
1 lb (0.5 kg)
Spool Canister
#132 230
Ideal for use
with XR guns
if a small job
arises requiring a different wire size and/or
wire type that does not justify a 12 in
(305 mm) spool of wire. The XR feed cable is
removed if the spool canister is being used.
(Canister accommodates 4 in [102 mm]
spools of wire.)
XR-Pistol Gun Barrels (Air-Cooled)
50 Degree Curved Barrel-A
#195 229 6 in (152 mm)
Used with .030 –1/16 in (0.8 –1.6 mm)
wire. Kits supplied with liner that
accommodates all wire sizes.
10 in Flex Head-A #195 228
For .030 –1/16 in (0.8 –1.6 mm) wire. Used
in place of the standard straight barrel. Flexible
head tube bends 60 degrees in any direction
for easier joint access and improved operator
comfort. Supplied with liners. Uses FasTip™
contact tips.
10 in Head Tube-A #195 227
Ideal when a longer reach is required.
Replacement Liners for Air-Cooled Barrels
(Order from Miller Service Parts.)
For 6 in Curved Barrel
#212 411 .030 thru 1/16 in
(0.8 thru 1.6 mm) wire
For Flex Head or 10 in Head Tube
#212 401 .030 thru 1/16 in
(0.8 thru 1.6 mm) wire
50 Degree Curved Nozzle Kit-A
#147 174
Attaches to standard gun barrel assembly
for access to confined weld joint areas.
Used with .030 –1/16 in (0.8 –1.6 mm)
wire. Kit includes two of each size contact
tips to accommodate all wire sizes, Nozzle
Adapter Kit (#193 794) and curved nozzle.
Uses standard straight barrel head tube liner.
Replacement Contact Tips for Curved
Nozzle (Order from Miller Service Parts.)
#148 155 .030 and .035 in
(0.8 and 0.9 mm) wire
#148 154 .047 in (1.2 mm) wire
#148 156 1/16 in (1.6 mm) wire
XR-Pistol Gun Barrels (Water-Cooled)
Replacement Liners for Water-Cooled
Barrels (Order from Miller Service Parts.)
50 Degree Curved Barrel-W
#130 843 6 in (152 mm)
Used with .030 –1/16 in (0.8 –1.6 mm)
wire. Kits supplied with liner that
accommodates all wire sizes.
6
For 6 in Curved Barrel
#212 411 .030 thru 1/16 in
(0.8 and 1.6 mm) wire
For 10 in Straight Barrel
#212 401 .030 thru 1/16 in
(0.8 and 1.6 mm) wire
10 in Straight Barrel-W #130 841
Used with .030 –1/16 in (0.8 –1.6 mm)
wire. Kits supplied with liner that
accommodates all wire sizes.
Typical Welding Systems for Aluminum MIG Welding
Conventional Aluminum MIG System
CP-252TS with XR™ Control and 30 ft XR-A Edge Gun
#950 704
Aluminum MIG and Pulsed MIG System
Invision™ 354MP with XR™ Control and 30 ft XR-A Edge Gun
#950 705
Note: For high-current pulse welding,
water-cooled system recommended.
Typical Installations
10 ft (3 m) 24 VAC
and contactor cord supplied with feeder
Miller CV or CV/CC power
source equipped with a 14-pin
receptacle and 24 VAC power.
XR
Control
or
10 ft (3 m) gas hose included
15 or 30 ft cable
(50 ft available for XR-Edge Gun)
PSA-2
115 / 24 VAC
Miller CV or competitive
CV power source with
115 VAC power
10 ft (3 m) 24 VAC
and contactor cord supplied with feeder
Contactor
115 VAC
XR
Control
or
10 ft (3 m) gas hose included
15 or 30 ft cable
(50 ft available for XR-Edge Gun)
7
Ordering Information
How to Assemble a System
1
Pick a Control
Standard or with Options
2
Pick a Gun Style
Gooseneck or Pistol
15, 30 or 50 ft Cable
Air- or Water-Cooled
or
3
Pick a FasTip™/Drive Roll Kit
.030, .035, .040, .047 or .062 in
(Kits consist of gun drive rolls,
control box drive rolls and five
FasTip contact tips.)
Recommended Power Sources*
Regency® 250
Lit. Index No. DC/12.6
CP-252TS
Lit. Index No. DC/13
Deltaweld ® Series
Lit. Index No. DC/16.2
Lit. Index No. DC/18.8
XMT® 304
Invision™ 354 MP Lit. Index No. DC/23
Trailblazer ® 301 G Lit. Index No. ED/4.77
Big Blue Air Pak™
Lit. Index No. ED/10.5
Lit. Index No. ED/10.6
PipePro™
Lit. Index No. ED/4.8
Trailblazer® 301 D
*Other power sources may be used.
Important note: The products and
descriptions mentioned in this
literature are for use with XR Control
systems with serial #KK309906 or
higher. To confirm compatibility of
any products listed here with older
equipment, please contact the factory
at 1-920-735-4505.
(Use the 3-step process below to assemble a complete system.)
Equipment
XR™ Control
Description
Qty.
#181 538
#181 538-01-1
#181 538-03-3
#181 538-04-2
CP-252TS with XR™ Control #950 704
and XR-Edge Gun Package
Invision™ 354MP with
#950 705
XR™ Control and
XR-Edge Gun Package
Standard model w/digital display
Standard model w/digital display & w/CE
W/digital display, voltage control & gas flow meter
W/digital display, voltage control & gas flow mtr w/CE
Conventional aluminum MIG package
Gun included — Drive roll kit required
Aluminum MIG and pulsed MIG package
Gun included — Drive roll kit required
XR-A Edge Gun
(Air-Cooled)
#181 534
#181 535
#181 537
#181 531
#181 532
#181 533
#198 127
#198 128
#198 129
#198 130
#195 208
#195 207
#195 206
#195 205
#195 204
#195 213
#195 212
#195 211
#195 210
#195 209
15 ft (4.6 m) cable
30 ft (9 m) cable
50 ft (15.2 m) cable
15 ft (4.6 m) cable
30 ft (9 m) cable
50 ft (15.2 m) cable
15 ft (4.6 m) cable
30 ft (9 m) cable
15 ft (4.6 m) cable
30 ft (9 m) cable
.030 in (0.8 mm)
.035 in (0.9 mm)
.040 in (1.0 mm)
.047 in (1.2 mm)
.062 in (1.6 mm)
.030 in (0.8 mm)
.035 in (0.9 mm)
.040 in (1.0 mm)
.047 in (1.2 mm)
.062 in (1.6 mm)
#194 027
#193 276
#193 274
#209 867
#193 271
#193 272
#193 278
#197 793
#193 279
Field
Field
Field. For XR Control prior to serial #LC122752
Field. Required for CC, competitive or
non-solid-state Miller power sources
Field. For 15 ft (4.6 m) and 30 ft (9 m) guns
Field. For 50 ft (15.2 m) gun
Field
Field w/CE
Field
#194 039
Field
XR-W Edge Gun
(Water-Cooled)
XR-A Pistol Gun
(Air-Cooled)
XR-W Pistol Gun
(Water-Cooled)
XR-Edge Gun
FasTip™/Drive Roll Kits
(One required — See page 5
for Isolated Drive Rolls)
XR-Pistol Gun
FasTip™/Drive Roll Kits
(One Required)
Options
Voltage Control
Dual Schedule Control
Digital Display V/WFS
Remote Volt Sense Lead
Dual Schedule Switch
Gas Flowmeter
Spot Weld/Burnback Control
Water Flow
Shutdown Switch
Accessories
Optima MIG Pulse Control
PSA-2 Control
Extension Cords
Water Coolant Systems
Cable Cover
Spool Canister
XR-Pistol Gun Barrels
Date:
Distributed by:
Litho in USA
Stock No.
Important: The XR Control and specific type and length gun must be ordered separately.
Also order proper FasTip™/Drive Roll Kit below for the size wire being used.
#043 389
#141 604
#118 677
#118 678
#132 230
All XR-Edge guns
have CE approval.
For older power sources w/ 115 V feeder power
See XR Control Accessories on page 3
See Lit. Index No. AY/7.2
15 ft (4.5 m)
30 ft (9 m)
See page 6
Total Quoted Price:
Price