Miller Electric OM-1589 manual Standard Pulse Welding Programs, Program 1 − Aluminum

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SECTION 9 − STANDARD PULSE WELDING PROGRAMS

NOTE

Apk = Peak Amperage, Abk = Background Amperage,

PPS = Pulses Per Second, PWms = Pulse Width (milliseconds).

9-1.Program 1 − Aluminum

Wire Size/Type: .030” ER 4043			Gas: 100% Argon / 15-80 CFH				Gun Model: 30 Ft W ater-Cooled

IPM / MPM	Apk	Abk		PPS	PWms	Volts	COMMENTS


875	360	90		234	2.2	28.0

820	355	87		228	2.1	26.8

765	347	82		217	2.0	26.2

710	345	80		215	1.9	25.8

655	330	75		210	1.8	25.8

600	315	68		200	1.7	24.0

545	300	61		190	1.6	23.0

490	300	60		180	1.5	22.0

435	290	54		158	1.4	24.6

380	275	49		146	1.3	24.6

325	265	43		136	1.2	20.7

270	255	37		135	1.1	17.8

215	245	31		117	1.1	16.6

160	230	27		71	1.1	17.6

105	230	19		30	1.0	20.2

9-2.Program 2 − Aluminum

Wire Size/Type: .035” ER 4043			Gas: 100% Argon / 20-40 CFH				Gun Model: 30 Ft W ater-Cooled

IPM / MPM	Apk	Abk		PPS	PWms	Volts	COMMENTS


875	385	162		230	2.2	28.4

820	380	156		220	2.1	28.0

765	375	150		210	2.0	26.8

710	367	144		200	1.9	26.8

655	365	140		190	1.8	26.8

600	355	130		178	1.7	26.6

545	345	118		160	1.6	26.0

490	330	108		145	1.5	25.1

435	314	90		143	1.4	23.8

380	294	75		140	1.3	23.3

325	285	60		135	1.2	25.1

270	280	43		137	1.2	19.6

215	270	42		116	1.1	17.9

160	250	35		77	1.1	18.6

105	250	25		35	1.1	18.4

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Contents Processes OM-1589Description From Miller to You Table of Contents 11-1 10-110-2 11-2Standards DirectivesDeccon 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 blessuresInformation sur les champs électromagnétiques Principales normes de sécuritéConsignes 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, 3/4Pin Plug Information Rear Panel ConnectionsPin 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-1589Operational Terms − OperationPulse 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 programsSystem Setup Display Parameters − System SetupDisplay Setting Program 1 − Aluminum − Standard Pulse Welding ProgramsProgram 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 IPM Teach Point Redefining Teach PointsRedefining 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 shownRelease Trigger Error Display Error DisplaysNo 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