Miller XR Python 25 Ft. User manual

200 Ampere Push-Pull Welding Gun
XR -A Python 25 Ft.
Processes
Description
MIG (GMAW) Welding
OM-1500-17 218 022G
2006−06
®
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 9001:2000 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 4/05

TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS −READ BEFORE USING 1. . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. GMAW Gun Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMF INFORMATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 −DEFINITIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Symbols And Definitions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 −INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Gun Lead Connections 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 −OPERATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls and Settings 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Drive Roll Removal/Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Idler Roll Removal/Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 −MAINTENANCE & TROUBLESHOOTING 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Troubleshooting Guide 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Troubleshooting Table 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 −ELECTRICAL DIAGRAMS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 −PARTS LIST 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 −OPTIONS AND ACCESSORIES 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY

dec_wire_6/05
Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
NOTE
Manufacturer:European Contact:
Miller Electric Mg. Co. Mr. Danilo Fedolfi,
1635 W. Spencer St. Managing Director
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
Phone: [phone] Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: [phone]
Fax: [phone]
European Contact Signature:
Declares that the product: Python®
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic Compatibility (EMC) Directive: 89/336/EEC
Standards
Arc Welding Equipment −Part 5: Wire Feeders. IEC 60974-5 Ed. 1
Arc Welding Equipment −Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10 August 2002
Arc Welding Equipment −Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Degrees Of Protection Provided By Enclosure (IP Code) IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems −
Part 1: Principles, Requirements and Tests: IEC 60664-1 Ed. 1.1
Arc Welding Equipment −Part 7: Torches. IC 60974-7 Ed.1
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.

OM-1500-17 Page 1
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.
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.
YMarks a special safety message.
.Means NOTE; not safety related.
1-2. GMAW Gun Hazards
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information found in the wire feeder
and welding power source Owner’s Manuals. Read and follow all safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
GMAW WELDING can be hazardous.
ARC RAYS can burn eyes and skin.
1. Wear welding helmet with correct shade of filter.
2. Wear correct eye and body protection.
3. Cover exposed skin with spatter-resistant
clothing.
ELECTRIC SHOCK can kill.
1. Always wear dry insulating gloves.
2. Insulate yourself from work and ground.
3. Do not touch live electrode or electrical parts.
4. Repair or replace worn, damaged, or cracked
gun or cable insulation.
5. Turn off welding power source before changing
contact tip or gun parts.
6. Keep all covers and handle securely in place.
WELDING can cause fire or explosion.
1. Do not weld near flammable material.
2. Do not weld on closed containers.
3. Watch for fire; keep extinguisher nearby.
NOISE can damage hearing; SOME
APPLICATIONS, SUCH AS PULSING,
are noisy.
1. Check for noise level limits exceeding those
specified by OSHA.
2. Use approved ear plugs or ear muffs if noise level
is high.
3. Warn others nearby about noise hazard.
HOT SURFACES can burn skin.
1. Allow gun to cool before touching.
2. Do not touch hot metal.
3. Protect hot metal from contact by others.
FUMES AND GASES can be hazardous
to your health.
1. Keep your head out of the fumes.
2. Ventilate area, or use breathing device.
3. Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
WELDING WIRE can cause puncture
wounds.
1. Keep hands and body away from gun tip when
trigger is pressed.
BUILD UP OF GAS can injure or
kill
1. Shut off shielding gas supply when not in
use.
2. Always ventilate confined spaces or use
approved air-supplied respirator.

OM-1500-17 Page 2
EMF INFORMATION
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): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understandingdoes not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
NOTE
mod10.1 4/93

OM-1500-17 Page 3
SECTION 2 −DEFINITIONS
1 1.1 1.2 1.3
3 3.1 3.2 3.3
4 4.1 +
22.1 2.2
+
+
56
+
2.3
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 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Disconnect input plug or
power before working on
machine.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Don’t weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
5 Become trained and read the
instructions before working on
the machine or welding.
6 Do not remove or paint over
(cover) the label.
2-1. Warning Label Definitions
ABC

OM-1500-17 Page 4
2-2. Symbols And Definitions
Some symbols are found only on CE products.
Note
AAmperes VVolts AlternatingCurrent XDuty Cycle
IP Degree Of
Protection Hz Hertz Circuit Breaker Wire Feed
Jog Output Trigger Gun
Press To Set Increase Trigger Hold On Trigger Hold Off
Purge Spot Weld Time Percent Run-In
Burnback Time U1Primary Voltage U2Load Voltage Read Instructions
I1Primary Current I2Rated Current Line Connection Water (Coolant) In-
put
Water (Coolant)
Output Fuse Continuous Spot Welding

OM-1500-17 Page 5
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)
Ref. 803 870-A
Shipping Weight
Approximately 19.29 lbs (8.29 kg)
3-2. Gun Lead Connections
Power Cable - A #2 AWG power cable is used. The gun end of the cable has a fitting crimped to the copper cable
strands. This fitting is then threaded into the gun body. The cabinet end of the power cable is incorporated into the
Power Pin connector.
Conduit - Poly-lined conduit, for feeding aluminum wire. The longer fitting with a shallow groove is used on the gun
end. A set screw located on top of the gun handle secures the conduit in place. The cabinet end of the conduit is incor-
porated into the Power Pin connector.
Gas Hose - The gas hose is pushed over a barbed fitting on the gun body and secured with a plastic tie wrap. The
cabinet end of the gas hose is incorporated into the Power Pin connector.
Electric Cable - A multi-conductor control cable is used. The gun end of the cable is secured with a cable clamp and
the wires are connected to the potentiometer, the micro switch, the motor and the gun body mechanically. The cabinet
end of the control cable uses a 10-Pin, Amphenol connector.

OM-1500-17 Page 6
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 Trigger
3 Trigger Sensitivity
Adjustment Screw
The amount of trigger level travel
can be shortened for quicker re-
sponse action.
A more sensitive trigger lever is
produced by reducing the gap be-
tween the trigger lever and the mi-
cro switch lever. Turning the trig-
ger sensitivity adjustment screw
clockwise closes the gap between
the trigger lever and the micro
switch lever. This will enable the
operator to increase the sensitivity
of the trigger level.
Sensitivity adjustment - With the
wire feeder turned on (with or with-
out welding wire loaded), turn the
screw clockwise until the micro−
switch is activated. Once acti-
vated, the gun and wire feeder mo-
tors will begin feeding wire. Turn
the screw counter clockwise until
the system is deactivated and ad-
justed to the operators’ liking.
Close top cover.
803 870-A
1
Tools Needed:
2
3