Miller Electric OM-1589 Typical Water-Cooled System Connections, Tools Needed 16, 5/8, 11/16, 3/4

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3-3. Typical Water-Cooled System Connections

1

2

14

3

4

13

5

6

12

7

8	11

10

9

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)

8Water-Cooled Gun

9Wire Feeder

10Coolant Supply

11Coolant In Hose

12Coolant Out Hose

Connect hoses between coolant supply and wire feeder.

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

13Gas Hose

14Gas Cylinder

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

Tools Needed:

9/16, 5/8, 11/16, 3/4 in

801 810 / Ref. 175 086 / Ref. 180 311-B

OM-1589 Page 12

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Contents OM-1589 ProcessesDescription From Miller to You Table of Contents 11-1 10-110-2 11-2Directives StandardsDeccon 11/96 Page Arc Welding Hazards Symbol UsageMarks a special safety message Electric Shock can killFlying Metal can injure eyes ARC Rays can burn eyes and skinWelding can cause fire or explo- sion Buildup of GAS can injure or killPrincipal Safety Standards EMF Information About PacemakersUN Choc Électrique peut tuer Signification des symboles− Consignes DE Securite − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent pro- voquer des brûlures graves LE Soudage peut provoquer un incendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïe’EMPLOI Excessif peut Risque D’INCENDIE OULA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiquesConsignes relatives aux stimulateurs cardiaques Drive rolls can injure fingers Disconnect input plug or power before working on machine− Definitions Keep your head out of the fumesSymbols And Definitions Manufacturer’s Rating Label for CE ProductsType of Input Welding Power Wire Feed − InstallationSpecifications Welding Overall WeightTypical Water-Cooled System Connections Tools Needed 16, 5/8, 11/16, 3/4Rear Panel Connections Pin Plug InformationPin Pin Information Tions directly to gun hose Internal Connections for Water-Cooled GunInternal Connections for Air-Cooled Gun To gun partsWater-Cooled Guns Front Panel Connections for GunTools Needed 11/16, 1-1/8 Water-Cooled Model Shown Air-Cooled GunTorque Switch Adjusting Contact Tip PositionSetting Torque Switch Removing Top Cover of GunInstalling Wire Spool Wire Spool Top Cover Pressure Roll Assembly Gun Contact TipThreading Welding Wire Through Feeder Hub Tension Adjustment150 mm Open tension arm Cally live when gunWire Tools Needed OM-1589− Operation Operational TermsPulse Welding Terms Front Panel Controls Side and Rear Panel Controls Gun Controls− Setting Sequence Parameters Sequence Parameters in a Program− Setting Dual Schedule Parameters Selecting Dual Schedule PairData Card Terms − Using the Optional Data CardDual Schedule Switch Diagrams AdapterCard Displays Installing Data CardWire feeder memory 3 seconds and the 8 programs− System Setup System Setup Display ParametersDisplay Setting − Standard Pulse Welding Programs Program 1 − AluminumProgram 2 − Aluminum Gas 100% Argon / 20-Max CFH Program 3 − AluminumProgram 4 − Aluminum 24.5 435 32523.2 490 290 Program 5 − AluminumProgram 6 − Aluminum Gas 100% Argon / 20-45 CFH875 485 140 250 31.5 820 470 135 240 30.9 765 450 Program 8 AluminumProgram 7 − Aluminum 21.2 160 305 19.6 105 300 22.2− Teach Points Teach Points ExplainedRedefining Teach Points Redefining IPM Teach PointRedefining Pulse Parameters Flowrate CFHL/min Date Program Number Wire Size/TypeSerial Number Wire Feeder PositiveFeeder Drive Assembly Maintenance − Maintenance and TroubleshootingRoutine Maintenance Disconnect power before maintainingGun Drive Assembly Maintenance Changing Gun Contact Tip and LinerBarrel Extension Removing Air-Cooled Contact Tip AdapterRemoving Water-Cooled Contact Tip Adapter Remove as shownError Displays Release Trigger Error DisplayNo Volt Sensed Error Display Using Self Test E s s OM-1589Filter, and clean fittings TroubleshootingDisconnect power before troubleshooting Trouble RemedyOM-1589 − Electrical Diagram Circuit Diagram184 771-A Circuit Diagram For Gun OM-1589 Main Assembly ListPLG1 PLG81 Motor & Wire Drive Motor & Wire Drive -1 ItemPanel, Front w/Components Panel, Front w/Components -1 ItemPC60 PC40Barrel Assembly 137 Barrel ASSEMBLY, water cooled XRM-15W & 30W models 34 33 13−5 48Fig Includes Item133 Item Dia Part Mkgs Description Quantity Support ServiceYour distributor also gives Step of the wayMiller Electric Mfg. Co To locate distributor nearest you call 1-800-4-A-Miller