Miller Electric OM-1589 manual Table of Contents

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WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

OM-1589

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING		1
1-1.	Symbol Usage	1
1-2.	Arc Welding Hazards	1
1-3. Additional Symbols For Installation, Operation, And Maintenance		3
1-4.	Principal Safety Standards	3
1-5.	EMF Information	4

SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT UTILISATION		5
1-1.	Signification des symboles	5
1-2. Dangers relatifs au soudage à l’arc		5
1-3.	Dangers supplémentaires en relation avec l’installation, le fonctionnement
	et la maintenance	7
1-4.	Principales normes de sécurité	8
1-5.	Information sur les champs électromagnétiques	8

SECTION 2 − DEFINITIONS		9
2-1.	Warning Label Definitions	9
2-2.	Manufacturer’s Rating Label for CE Products	10
2-3.	Symbols And Definitions	10

SECTION 3 − INST ALLATION		11
3-1.	Specifications	11
3-2.	Typical Air-Cooled System Connections	11
3-3. Typical Water-Cooled System Connections		12
3-4.	Rear Panel Connections	13
3-5.	14-Pin Plug Information	13
3-6.	Internal Connections for Water-Cooled Gun	14
3-7.	Internal Connections for Air-Cooled Gun	14
3-8.	Front Panel Connections for Gun	15
3-9.	Removing Top Cover of Gun	16
3-10.	Adjusting Contact Tip Position	16
3-11.	Setting Torque Switch	16
3-12.	Installing Wire Spool	17
3-13.	Threading Welding Wire Through Feeder	18
3-14.	Threading Welding Wire Through Feeder (Continued)	19

SECTION 4 − OPERATION		20
4-1.	Operational Terms	20
4-2.	Pulse Welding Terms	20
4-3.	Front Panel Controls	21
4-4. Side and Rear Panel Controls		22
4-5.	Gun Controls	22

SECTION 5 − SETTING SEQUENCE PARAMETERS		23
5-1. Sequence Parameters in a Program		23
SECTION 6 − SETTING DUAL SCHEDULE PARAMETERS		24
6-1. Selecting Dual Schedule Pair		24
6-2.	Dual Schedule Switch Diagrams	25
SECTION 7 − USING THE OPTIONAL DATA CARD		25
7-1.	Data Card Terms	25
7-2.	Installing Data Card	26
7-3.	Card Displays	26

(Continued)

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Contents OM-1589 ProcessesDescription From Miller to You Table of Contents 11-2 10-110-2 11-1Directives StandardsDeccon 11/96 Page Electric Shock can kill Symbol UsageMarks a special safety message Arc Welding HazardsBuildup of GAS can injure or kill ARC Rays can burn eyes and skinWelding can cause fire or explo- sion Flying Metal can injure eyesPrincipal Safety Standards About Pacemakers EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Securite − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un incendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent pro- voquer des brûlures gravesDES Organes Mobiles peuvent provoquer des blessures Risque D’INCENDIE OULA Chute DE L’APPAREIL peut blesser ’EMPLOI Excessif peutPrincipales normes de sécurité Information sur les champs électromagnétiquesConsignes relatives aux stimulateurs cardiaques Keep your head out of the fumes Disconnect input plug or power before working on machine− Definitions Drive rolls can injure fingersManufacturer’s Rating Label for CE Products Symbols And DefinitionsWelding Overall Weight − InstallationSpecifications Type of Input Welding Power Wire FeedTools Needed 16, 5/8, 11/16, 3/4 Typical Water-Cooled System ConnectionsRear Panel Connections Pin Plug InformationPin Pin Information To gun parts Internal Connections for Water-Cooled GunInternal Connections for Air-Cooled Gun Tions directly to gun hoseAir-Cooled Gun Front Panel Connections for GunTools Needed 11/16, 1-1/8 Water-Cooled Model Shown Water-Cooled GunsRemoving Top Cover of Gun Adjusting Contact Tip PositionSetting Torque Switch Torque SwitchWire Spool Top Cover Pressure Roll Assembly Gun Contact Tip Installing Wire SpoolHub Tension Adjustment Threading Welding Wire Through FeederTools Needed OM-1589 Cally live when gunWire 150 mm Open tension arm− Operation Operational TermsPulse Welding Terms Front Panel Controls Gun Controls Side and Rear Panel ControlsSequence Parameters in a Program − Setting Sequence ParametersSelecting Dual Schedule Pair − Setting Dual Schedule ParametersAdapter − Using the Optional Data CardDual Schedule Switch Diagrams Data Card Terms3 seconds and the 8 programs Installing Data CardWire feeder memory Card Displays− System Setup System Setup Display ParametersDisplay Setting − Standard Pulse Welding Programs Program 1 − AluminumProgram 2 − Aluminum 24.5 435 325 Program 3 − AluminumProgram 4 − Aluminum Gas 100% Argon / 20-Max CFHGas 100% Argon / 20-45 CFH Program 5 − AluminumProgram 6 − Aluminum 23.2 490 29021.2 160 305 19.6 105 300 22.2 Program 8 AluminumProgram 7 − Aluminum 875 485 140 250 31.5 820 470 135 240 30.9 765 450Teach Points Explained − Teach PointsRedefining Teach Points Redefining IPM Teach PointRedefining Pulse Parameters Positive Date Program Number Wire Size/TypeSerial Number Wire Feeder Flowrate CFHL/minDisconnect power before maintaining − Maintenance and TroubleshootingRoutine Maintenance Feeder Drive Assembly MaintenanceChanging Gun Contact Tip and Liner Gun Drive Assembly MaintenanceRemove as shown Removing Air-Cooled Contact Tip AdapterRemoving Water-Cooled Contact Tip Adapter Barrel ExtensionError Displays Release Trigger Error DisplayNo Volt Sensed Error Display E s s OM-1589 Using Self TestTrouble Remedy TroubleshootingDisconnect power before troubleshooting Filter, and clean fittingsOM-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 Step of the way ServiceYour distributor also gives SupportTo locate distributor nearest you call 1-800-4-A-Miller Miller Electric Mfg. Co