Miller Electric OM-1589 manual From Miller to You

Page 2

Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System Standard.

From Miller to You

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 which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

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 catalog sheets. To locate your nearest distributor call 1-800-4-A-Miller.

Working as hard as you do

−every power source from Miller is backed by the most hassle-free warranty in the business.

Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P.

Image 2

Contents Description OM-1589Processes From Miller to You Table of Contents 11-1 10-110-2 11-2Deccon 11/96 DirectivesStandards 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 blessuresConsignes relatives aux stimulateurs cardiaques Principales normes de sécuritéInformation sur les champs électromagnétiques 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, 3/4Pin Pin Information Rear Panel ConnectionsPin Plug 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-1589Pulse Welding Terms − OperationOperational 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 programsDisplay Setting − System SetupSystem Setup Display Parameters Program 2 − Aluminum − Standard Pulse Welding ProgramsProgram 1 − 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 Pulse Parameters Redefining Teach PointsRedefining IPM Teach Point 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 shownNo Volt Sensed Error Display Error DisplaysRelease Trigger 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