Miller Electric OM-1589 manual Installation, Specifications, Typical Air-Cooled System Connections

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SECTION 3 − INSTALLATION

3-1. Specifications

	Type of Input	Welding Power	Wire Feed	Wire Diameter	Welding	IP	Overall	Weight
	Power	Source Type	Speed Range	Range	Circuit Rating	Rating	Dimensions


		Constant Voltage (CV)		.030 To 1/16 in	100 Volts, 400		Length: 21-1/4 in
		DC For GMAW Or					(540 mm)	Net: 48 lb
	24 Volts AC			(0.8 To 1.6 mm)
		Constant Voltage(CV) /	70 To 875 ipm		Amperes,		Width: 9-1/2 in	(21.8 kg)
	Single-Phase
		Constant Current (CC) DC	(1.8 To 22.2		100% Duty	IP 23
	3 Amperes			Max Spool			(241 mm)
		For GMAW-P	mpm)		Cycle			Ship: 56 lb
	50/60 Hertz			Capacity: 12 in			Height: 16 in
		All Need 14-Pin And						(24.5 kg)
				(305 mm)
		Contactor Control					(406 mm)

3-2. Typical Air-Cooled System Connections

1

Tools Needed:

9/16, 5/8, 3/4 in

2

11

3

4

5

6

10

7

8

1300/400 Ampere Model CC/CV Inverter Welding Power Source

.Use settings shown for both pulse MIG welding and MIG welding.

2450 Ampere Model CV Inverter Welding Power Source

System can be set up with a variety of conventional Constant Voltage (CV) welding power sources.

314-Pin Plug And Interconnecting Cord

4Positive (+) Weld Cable

5Negative (−) Weld Cable

Select and prepare weld cables ac- cording to welding power source Owner’s Manual.

6Workpiece

7Voltage Sensing Lead (Optional Use)

8Air-Cooled Gun

9Wire Feeder

YDo not use gas pressure above 50 psi (345 kPa) or me- chanical gas valve in gun can leak.

10Gas Hose

11Gas Cylinder

Route hose from regulator/flowme- ter and connect to shielding gas valve fitting.

9

801 809 / Ref. 175 086 / Ref. 180 311-B

OM-1589 Page 11

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Contents Description OM-1589Processes From Miller to You Table of Contents 10-2 10-111-1 11-2Deccon 11/96 DirectivesStandards Page Marks a special safety message Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explo- sion ARC Rays can burn eyes and skinFlying Metal can injure eyes Buildup of GAS can injure or killPrincipal Safety Standards About Pacemakers EMF Information− Consignes DE Securite − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un incendie ou une explosionDES Pièces Chaudes peuvent pro- voquer des brûlures graves LE Bruit peut affecter l’ouïeLA Chute DE L’APPAREIL peut blesser Risque D’INCENDIE OU’EMPLOI Excessif peut DES Organes Mobiles peuvent provoquer des blessuresConsignes relatives aux stimulateurs cardiaques Principales normes de sécuritéInformation sur les champs électromagnétiques − Definitions Disconnect input plug or power before working on machineDrive rolls can injure fingers Keep your head out of the fumesManufacturer’s Rating Label for CE Products Symbols And DefinitionsSpecifications − InstallationType of Input Welding Power Wire Feed Welding Overall WeightTools Needed 16, 5/8, 11/16, 3/4 Typical Water-Cooled System ConnectionsPin Pin Information Rear Panel ConnectionsPin Plug Information Internal Connections for Air-Cooled Gun Internal Connections for Water-Cooled GunTions directly to gun hose To gun partsTools Needed 11/16, 1-1/8 Water-Cooled Model Shown Front Panel Connections for GunWater-Cooled Guns Air-Cooled GunSetting Torque Switch Adjusting Contact Tip PositionTorque Switch Removing Top Cover of GunWire Spool Top Cover Pressure Roll Assembly Gun Contact Tip Installing Wire SpoolHub Tension Adjustment Threading Welding Wire Through FeederWire Cally live when gun150 mm Open tension arm Tools Needed OM-1589Pulse Welding Terms − OperationOperational Terms Front Panel Controls Gun Controls Side and Rear Panel ControlsSequence Parameters in a Program − Setting Sequence ParametersSelecting Dual Schedule Pair − Setting Dual Schedule ParametersDual Schedule Switch Diagrams − Using the Optional Data CardData Card Terms AdapterWire feeder memory Installing Data CardCard Displays 3 seconds and the 8 programsDisplay Setting − System SetupSystem Setup Display Parameters Program 2 − Aluminum − Standard Pulse Welding ProgramsProgram 1 − Aluminum Program 4 − Aluminum Program 3 − AluminumGas 100% Argon / 20-Max CFH 24.5 435 325Program 6 − Aluminum Program 5 − Aluminum23.2 490 290 Gas 100% Argon / 20-45 CFHProgram 7 − Aluminum Program 8 Aluminum875 485 140 250 31.5 820 470 135 240 30.9 765 450 21.2 160 305 19.6 105 300 22.2Teach Points Explained − Teach PointsRedefining Pulse Parameters Redefining Teach PointsRedefining IPM Teach Point Serial Number Wire Feeder Date Program Number Wire Size/TypeFlowrate CFHL/min PositiveRoutine Maintenance − Maintenance and TroubleshootingFeeder Drive Assembly Maintenance Disconnect power before maintainingChanging Gun Contact Tip and Liner Gun Drive Assembly MaintenanceRemoving Water-Cooled Contact Tip Adapter Removing Air-Cooled Contact Tip AdapterBarrel Extension Remove as shownNo Volt Sensed Error Display Error DisplaysRelease Trigger Error Display E s s OM-1589 Using Self TestDisconnect power before troubleshooting TroubleshootingFilter, and clean fittings Trouble RemedyOM-1589 Circuit Diagram − Electrical Diagram184 771-A Circuit Diagram For Gun OM-1589 List Main AssemblyPLG1 PLG81 Motor & Wire Drive -1 Item Motor & Wire DrivePanel, Front w/Components -1 Item Panel, Front w/ComponentsPC40 PC60Barrel Assembly 137 Barrel ASSEMBLY, water cooled XRM-15W & 30W models Includes Item 34 33 13−5 48Fig133 Item Dia Part Mkgs Description Quantity Your distributor also gives ServiceSupport Step of the wayTo locate distributor nearest you call 1-800-4-A-Miller Miller Electric Mfg. Co