A M1-73 Spoolmatic XR Pistol Guns.qxd:A M1

Issued Feb. 2008 • Index No. M/1.73
Pistol Grip Guns
MIG Guns for
Aluminum Welding
Spoolmatic and XR -Pistol Guns
®
Quick
Specs
™
Heavy Industrial Applications
Processes
Emergency Vehicles
Recreational Vehicles
Trucks and Trailers
Boat/Yacht Building
Sign Manufacturers
MIG (GMAW) Welding
with aluminum wire and
other soft alloys
Pulsed MIG (GMAW-P)
with pulsing power source
Shipbuilding
Tool Boxes
Railcars
Fabrication
The Power of Blue .
®
Rated Output at
100% Duty Cycle
Spoolmatic 15A/30A: 200 A
XR-A Pistol: 200 A
XR-W Pistol: 400 A
Weight with
Cable Assembly
Spoolmatic 15A: 9 lb (4.1 kg)
Spoolmatic 30A: 14 lb (6.4 kg)
XR-A Pistol (15 ft): 10.9 lb (4.9 kg)
XR-A Pistol (30 ft): 18.5 lb (8.4 kg)
XR-W Pistol (15 ft): 11.6 lb (5.3 kg)
XR-W Pistol (30 ft): 19.2 lb (8.7 kg)
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.
Barrels are Roughneck® and Bernard®
Centerfire™ compatible. (See page 5 for
optional consumables.)
The Spoolmatic® Pistol Grip
Gun is an industrial, wellbalanced spool gun and features
a built-in gas valve, rotatable
canister, all-wire dual groove
drive roll and 15 ft (15A) or
30 ft (30A) cable reach. New
barrels are Roughneck and
Bernard Centerfire compatible.
The Spoolmatic® Pistol Grip Gun is
designed to be used with the WC-24
or WC-115 Weld Control as part of a
complete aluminum system.
A Complete System Consists of
the Following:
Spoolmatic Gun
(Includes .035–1/16 in dual drive
roll and two FasTip™ contact tips—
.035 in and 3/64 in )
WC-24 or WC-115 Weld Control
Recommended Miller 14-pin
power source
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.
The XR™-Pistol
Grip Gun is
designed to be
used with the
XR™-Control as
part of a pushpull system.
Patented quick-change, single-turn contact tip
provides excellent performance and ease of
replacement.
A Complete System Consists of
the Following:
The XR™-Pistol Grip Gun is
available in air- or water-cooled
versions with 15 or 30 ft (4.6 or
9 m) cable lengths. The replaceable
feed cable liner saves time and
money, while the trigger hold
helps eliminate hand strain.
Trigger hold reduces fatigue by allowing
operator to weld without holding trigger.
(Feature only available when XR-Pistol Grip
Gun is paired with XR-Control.)
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. (XR-Pistol Grip Gun only.)
XR-Pistol Grip Gun
XR™-Control
See Lit Index No. M/1.7.
FasTip™/Drive Roll Kit
Recommended Miller 14-pin
power source
Note: FasTip ™ Kits must be ordered
separately and consist of gun drive rolls,
control box drive rolls and five FasTip ™
contact tips.
Guns are warranted for 1 year, parts and labor.
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
®
Spoolmatic Pistol Grip Gun Specifications
(Subject to change without notice.)
Maximum Spool
Size Capacity
Model
Welding
Output Rating
Electrode Wire
Diameter Capacity
Wire Speed
Spoolmatic
15A
200 A at
100% Duty Cycle
.030 –1/16 in (0.8 –1.6 mm) aluminum
and hard wires up to .045 in (1.1 mm)
70 – 875 IPM
(1.8 – 22.2 m/min)
4 in (102 mm)
Spoolmatic
30A
Dimensions
H: 10-1/4 in (260 mm)
W: 2-1/2 in (64 mm)
L: 15-1/8 in (384 mm)
Net Weight with
Cable Assembly
9 lb (4.1 kg)
14 lb (6.4 kg)
®
Spoolmatic Pistol Grip Gun Specifications
(Air-Cooled Parts Breakdown and Gun Shown.)
1. Air-Cooled Assembly Kit #221 295
2. Head Tube Liner
#212 156
3. O-Ring .614 ID
#134 800
4. Head Tube (Air-cooled) #221 087
5. Barrel Pistol Insulator
#219 795
6. Outer Insulating Jacket #219 794
7. Nozzle Insulator
#232 284
8. Diffuser
#227 749
9. Contact Tip
(See consumables)
10. Nozzle (See optional consumables)
1
2
3
4
5
6
7
8
9
Genuine Miller Spoolmatic 30A Standard Consumables
10
(Order from Miller Service Parts.)
Wire Size (Aluminum)
FasTip Contact Tip
Spoolmatic Drive Rolls
Spoolmatic All-Wire Dual Groove Drive Rolls
Head Tube Liner
.030 in (0.8 mm)
#206 186 .041 in ID
#183 357
#136 135
#212 156
.035 in (0.9 mm)
#206 187 .047 in ID
#183 357
#136 135
.040 in (1.0 mm)
#206 188 .053 in ID
#183 357
#136 135
3/64 in (1.2 mm)
#206 189 .061 in ID
#183 358
#136 135
1/16 in (1.6 mm)
#206 190 .071 in ID
#183 358
#136 135
Each gun is shipped with .035 in and .047 in standard tips.
Typical Installations
Note: Cords and cables are supplied unless noted otherwise on drawings below. Refer to Owner’s Manual for complete installation instructions.
To connect the Spoolmatic 15A/30A and WC-24
control to older-style Miller or competitive CV power
sources that do not have a 24 VAC supply, the PSA-2
control #141 604 is required.
To connect Spoolmatic 15A/30A gun and WC-24
control to Millermatic® 200 and Spoolmate™ 200
power sources that have a 4-pin receptacle, order
adapter cord #042 236.
To connect the WC-115A control to older-style Miller
power sources having Hubbell or 5-pin contactor
control receptacles, the appropriate connector must
be ordered separately:
To connect to older-style Miller CC power sources having
a two-socket Hubbell connector, order plug #039 618.
If power source has a Miller 5-pin receptacle, order
#039 273 and #039 685.
To connect to older-style Miller CV power sources having
a two-prong Hubbell connector, order plug #039 635.
Note: These connectors are to replace the 14-pin
connector on the 10 ft interconnect contactor cord.
Internal wiring changes may be necessary.
2
Miller CV, DC
power source
with a 14-pin
receptacle and
24 VAC supply
WC-24
Control
10 ft (3 m)
Control Cord
Control Cord
Weld Power
Cable
Spoolmatic Gun
40 ft (12 m) Gas Hose
Gas Hose
WC-115A
Control
Control Cord
Weld Power Cable
Miller and competitive CC and/or CV,
DC power source/generator. If the
power source does not have a weld
output contactor, order the optional
WC-115 contactor.
Spoolmatic Gun
Weld Power Cable (not included)
10 ft (3 m) Contactor Cord (supplied on non-contactor unit)
10 ft (3 m) 115 VAC Power Cord (supplied)
™
XR -Pistol Grip Gun Specifications
Model
Welding Output Rating
XR-A Pistol
200 A at 100% Duty Cycle
XR-W Pistol
400 A at 100% Duty Cycle
A=Air-Cooled W=Water-Cooled
(Subject to change without notice.)
Electrode Wire
Diameter Capacity
Wire Speed
Dimensions
Net Weight with
Cable Assembly
.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)
15 ft Cable: 13 lb (5.9 kg)
30 ft Cable: 21 lb (9.5 kg)
15 ft Cable: 14 lb (6.4 kg)
30 ft Cable: 21.5 lb (9.8 kg)
Note: See back page for ordering XR-Pistol FasTip ™/Drive Roll Kits (one required).
Conforms to European standards.
Certified to both the Canadian and U.S. Standards for welding equipment.
™
XR -Pistol Grip Gun
(Air-Cooled Parts Breakdown and Gun Shown.)
1.
2.
3.
4.
5.
1, 2
3
4
5
6
7
8
9
10
6.
7.
8.
9.
10.
11.
11
Air-Cooled Assembly
Kit #221 295
Water-Cooled Assembly*
Kit #221 518
Head Tube Liner
#212 156
O-Ring .614 ID
#134 800
Head Tube (Air-cooled)
#221 087
Head Tube (Water-cooled)*
#221 519
Barrel Pistol Insulator
#219 795
Outer Insulating Jacket
#219 794
Nozzle Insulator
#232 284
Diffuser
#227 749
Contact Tip
(See consumables)
Nozzle
(See optional consumables)
*Order water-cooled parts from Miller Service Parts.
™
XR -Pistol Grip Standard Consumables (Air-Cooled Only) (Order from Miller Service Parts.)
Wire Size (Aluminum)
FasTip Contact Tip
Drive Rolls
All-Wire Dual Groove Drive Rolls
Head Tube Liner
Cable Liners
.030 in (0.8 mm)
#206 186 .041 in ID
#183 357
#136 135
#212 156
#191 065 15 or 30 ft (4.6 or 9 m)
.035 in (0.9 mm)
#206 187 .047 in ID
#183 357
#136 135
.040 in (1.0 mm)
#206 188 .053 in ID
#183 357
#136 135
3/64 in (1.2 mm)
#206 189 .061 in ID
#183 358
#136 135
1/16 in (1.6 mm)
#206 190 .071 in ID
#183 358
#136 135
Note: These are replacement consumables. See back page for initial setup kits.
Typical Installations
Note: Cords and cables are supplied unless noted otherwise on drawings below. Refer to Owner’s Manual for complete installation instructions.
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.
10 ft (3 m) gas hose included
PSA-2
115 / 24 VAC
Miller CV or competitive
CV power source with
115 VAC power
XR
Control
10 ft (3 m) 24 VAC
and contactor cord
supplied with feeder
Contactor
XR
Control
10 ft (3 m) gas hose included
115 VAC
3
Spoolmatic 15A/30A Spool Gun Controls
Spoolmatic 15A/30A Hook-Up Recommendations
CV Power Supply
Spoolmatic 15A/30A
Millermatic® Vintage*
Need Module #043 084
Millermatic® DVI™*, DVI2™, 210*, 212
Need Adapter Cable #195 287
(WFS controlled at machine)
Millermatic® 250X*, 251*, 252, 300 w/meters*, 350/350P,
Shopmate™ Series
Direct Hook-Up
Regency® 250*, CP Series, Shopmaster™*,
XMT®, Deltaweld® Series, Dimension™ Series
Need WC-24 #137 549
Bobcat™ Series, Miller Legend® 302
Need WC-115A #137 546-01-1
Trailblazer® 275 DC, 302, Trailblazer® Pro 350 D, PipePro™ 304
Need WC-24 #137 549
*Discontinued product.
When used with a CV source, it functions
as a constant-speed circuit.
Standard features include a wire run-in
control and a drive motor acceleration
control which ensure optimum arc starting
performance, regardless of the type of
power source being used. The WC-115A
comes with a 10 ft (3 m), wall-type plug
power cord.
WC-115A Weld Control
#137 546 Without contactor
#137 546-01-1 With contactor
This control operates on 115 VAC, and is
designed primarily for CC DC power sources.
It can also be used with CV power sources
or DC engine drives supplying 115 VAC.
When used with a CC source, the control
circuit functions in a voltage-sensing mode.
4
WC-115 Contactor Kit #137 548 Field
Recommended when using the Spoolmatic
gun and WC-115A control with power
sources that do not have a weld output
contactor. (This is installed in the WC-115A.)
Contactor Rating:
400 amps at 30% duty cycle
330 amps at 60% duty cycle
250 amps at 100% duty cycle
WC-24 Weld Control #137 549
Packaged in a compact, lightweight, nonmetallic enclosure, the WC-24 easily mounts
directly on the power source. It’s designed
for use with Miller CV power sources
supplying 24 VAC and 14-pin receptacles.
The control includes a board-mounted
potentiometer which can alter the drive
motor acceleration rate to optimize arc
starting performance.
®
™
™
Spoolmatic and XR Centerfire Series Consumables
Nozzles
FasTip Contact Tips
™
Screw-On Brass
#199 610 1/2 in orifice, tapered
#199 611 3/4 in orifice, straight
#199 612 3/4 in orifice, straight HD
#199 613 5/8 in orifice, tapered
#199 614 5/8 in orifice, , tapered HD
Screw-On Copper
#199 615 1/2 in orifice, tapered
#199 616 3/4 in orifice, straight
#199 617 3/4 in orifice, straight HD
#198 855 5/8 in orifice, tapered
#199 618 5/8 in orifice, tapered HD
#207 313 5/8 in orifice, tapered 15/16 OD
#209 035 3/8 in orifice, tapered
#209 036 1/2 in orifice, tapered
®
™
(Order from Miller Service Parts.)
(25 per package)
Heavy-Duty (Aluminum Wire)
#206 186 .030 in (0.8 mm)
#206 187 .035 in (0.9 mm)
#206 188 .040 in (1.0 mm)
#206 189 3/64 in (1.2 mm)
#206 191 1/16 in (1.6 mm)
Tapered (Aluminum Wire)
#209 026 .030/.035 in (0.8/0.9 mm)
#209 027 .035/.045 in (0.9/1.2 mm)
#209 029 3/64 in (1.2 mm)
#206 030 1/16 in (1.6 mm)
Gas Diffusers
#227 749 Standard
1/8 in tip recess for heavy-duty FasTip
contact tips.
#231 511
1/4 in tip recess for heavy-duty FasTip
contact tips.
#231 512
Flush tip for heavy-duty FasTip contact tips.
™
Spoolmatic and XR Centerfire Series Optional Consumables (Order from Miller Service Parts.)
T Series Contact Tips 1.5 in (38.1 mm)
T-030 .030 in (0.8 mm)
T-035 .035 in (0.9 mm)
T-039 .039 in (1.0 mm)
T-045 .045 in (1.2 mm)
T-052 .052 in (1.4 mm)
T-062 1/16 in (1.6 mm)
T-072 .068 – .072 in (1.7 – 1.8 mm)
TT Series Contact Tips 2 in (50.8 mm)
TT-030 .030 in (0.8 mm)
TT-035 .035 in (0.9 mm)
TT-045 .045 in (1.2 mm)
TT-052 .052 in (1.4 mm)
TT-062 1/16 in (1.6 mm)
Insulator 10012
4323R
Diffuser
D-1
DS-1
Nozzles
N-3414C Copper, 3/4 in I.D., 1/4 in tip recess
N-3418B Brass, 3/4 in I.D., 1/8 in tip recess
N-3414B Brass, 3/4 in I.D., 1/4 in tip recess
N-5814C Copper, 5/8 in I.D., 1/4 in tip recess
N-5818B Brass, 5/8 in I.D., 1/8 in tip recess
N-5814B Brass, 5/8 in I.D., 1/4 in tip recess
NS-5818B Brass, 5/8 in I.D., 1/8 in tip recess
NS-1218B Brass, 1/2 in I.D., 1/8 in tip recess
NS-1200B Brass, 1/2 in I.D., flush tip
NST-3818B Brass, 3/8 in I.D., 1/8 in tip recess
5/8 in I.D.
3/4 in I.D.
1/2 in I.D.
“T” Series Tip
(see chart)
Insulator
Diffuser
“T” Series Tip
#10012
#D-1
(see chart)
5/8 in I.D.
Large Nozzle (see chart)
Insulator
Diffuser
#4323R
#DS-1
3/8 in I.D.
Tapered Tip
“TT” Series Tip
(see chart)
Small Nozzle (see chart)
5
®
™
Spoolmatic and XR Gun Genuine Miller Accessories
Hose and Cable Extension Kits
#132 228 25 ft (7.6 m)
#132 229 50 ft (15 m)
Extends Spoolmatic 30A away from the
control box. Convenient plug-in connections.
Includes gas hose, control cord, and weld
power cable with International-style
insulated connector. For Spoolmatic only.
Cable Cover
#118 677 15 ft (4.6 m)
#118 678 30 ft (9 m)
50 ft cable cover is not available. Protects
gun hose and cable assembly from wear
and abrasion. Features a full length zipper.
For Spoolmatic or XR Guns.
Hardwire Liner Kit for Steel and Stainless
#198 377 For 15 or 30 ft guns (4.6 or 9 m)
Kit consists of gun head tube liner and feed
cable liner. Recommend using .030 –.045 in
mild steel, or stainless steel electrode wire.
For XR Pistol Grip Gun only.
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.)
Air-Cooled Gun Barrels
For Spoolmatic or XR Guns.
50 Degree Curved Barrel-A
#222 462 For non-FasTip ™ consumables
#300 161 For FasTip ™ consumables
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
Water-Cooled Gun Barrels
For XR Pistol Grip Gun only.
10 in Flex Head-A #222 735
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 #222 461
Ideal when a longer reach is required.
Replacement Liners for Air-Cooled Barrels
(Order from Miller Service Parts.)
For 6 in 50 Degree Curved Barrel
#212 411 .030 –1/16 in (0.8 –1.6 mm) wire
For Flex Head
#222 853 .030 –.035 in (0.8 – 0.9 mm) wire
#222 854 .047–.062 in (1.2 –1.6 mm) wire
For 10 in Head Tube
#212 401 .030 –1/16 in (0.8 –1.6 mm) wire
50 Degree Curved Nozzle Kit-A
(Order from Miller Service Parts.)
#147 174 For old-style multi-piece barrels
#300 161 For newer Roughneck®-style
barrels
Attaches to 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 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 (1.2 mm) wire
#148 156 1/16 in (1.6 mm) wire
50 Degree Curved Barrel-W #222 464
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.
Replacement Liners for
Water-Cooled Barrels
(Order from Miller Service Parts.)
For 6 in 50 Degree Curved Barrel
#212 411 .030 –1/16 in (0.8 –1.6 mm) wire
For 10 in Straight Barrel
#212 401 .030 –1/16 in (0.8 –1.6 mm) wire
10 in Straight Barrel-W #222 463
Used with .030 –1/16 in (0.8 –1.6 mm)
wire. Kits supplied with liner that
accommodates all wire sizes.
Notes
7
Ordering Information
Important notes:
Spoolmatic Guns require a WC-24 or
WC-115 Weld Control, unless used
on a machine that allows direct
hookup. Refer to chart on page 4.
XR-Pistol Grip Guns require a
XR-Control or may be used as a
direct connect to a Millermatic 252
and 350/350P.
Order the XR-Pistol Grip Gun
FasTip™/Drive Roll Kit for the size
wire being used. Kit consists of gun
drive rolls, control drive rolls and five
FasTip™ contact tips.
The products and descriptions
mentioned in this literature are for use
with XR-Control systems with serial
#KK309906 or higher. To confirm a
product’s compatibility with older
equipment, please contact the factory
at 1-920-735-4505.
Equipment
Stock No.
Description
Spoolmatic® 15A Spool Gun
#195 156
Includes 15 ft (4.6 m) cable
Spoolmatic® 30A Spool Gun
#130 831
Includes 30 ft (9 m) cable
Qty.
WC-24 Weld Control
#137 549
For Spoolmatic guns
WC-115A Weld Control
#137 546
#137 546-01-1
Without contactor. For Spoolmatic guns
With contactor. For Spoolmatic guns
WC-115 Contactor Kit
#137 548
Field
XR -A Pistol Grip Gun
(Air-Cooled)
#198 127
#198 128
15 ft (4.6 m) cable
30 ft (9 m) cable
XR™-W Pistol Grip Gun
(Water-Cooled)
#198 129
#198 130
15 ft (4.6 m) cable
30 ft (9 m) cable
XR™-Pistol Grip Gun
FasTip™/Drive Roll Kits
(Required when using pistol
grip gun. Includes gun drive
rolls, control box drive rolls
and five FasTip contact tips)
#195 213
#195 212
#195 211
#195 210
#195 209
.030 in (0.8 mm)
.035 in (0.9 mm)
.040 in (1.0 mm)
3/64 in (1.2 mm)
1/16 in (1.6 mm)
XR™-Control
(See Lit. Index No. M/1.7)
#181 538
#181 538-01-1
#181 538-03-3
#181 538-04-2
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 meter w/CE
Hose and Cable Extension Kits
#132 228
#132 229
25 ft (7.6 m). Spoolmatic only
50 ft (15 m). Spoolmatic only
Cable Cover
#118 677
#118 678
15 ft (4.6 m)
30 ft (9 m)
Spool Canister
#132 230
Hardware Liner Kit for
Steel and Stainless
#198 377
™
Consumables and Accessories
Consumables
For 15 or 30 ft (4.6 or 9 m) XR Pistol Grip guns only
Gun Barrels
See page 6
Water Coolant Systems
See Lit. Index No. AY/7.2
Date:
Distributed by:
Litho in USA
See pages 2–5
Total Quoted Price:
Price