Miller Electric OM-1589 manual 10-1, 10-2, 11-1, 11-2, 11-3, 11-5, 11-6, 11-8, 11-9

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SECTION 8 − SYSTEM SETUP		27
8-1.	System Setup Display Parameters	27
SECTION 9 − STANDARD PULSE WELDING PROGRAMS		28
9-1.	Program 1 − Aluminum	28
9-2.	Program 2 − Aluminum	28
9-3.	Program 3 − Aluminum	29
9-4.	Program 4 − Aluminum	29
9-5.	Program 5 − Aluminum	30
9-6.	Program 6 − Aluminum	30
9-7.	Program 7 − Aluminum	31
9-8.	Program 8 – Aluminum	31
SECTION 10 − TEACH POINTS		32
10-1.	Teach Points Explained	32
10-2.	Redefining Teach Points	33
SECTION 11 − MAINTENANCE AND TROUBLESHOOTING		35
11-1.	Routine Maintenance	35
11-2.	Feeder Drive Assembly Maintenance	35
11-3.	Changing Gun Contact Tip and Liner	36
11-4. Gun Drive Assembly Maintenance		36
11-5.	Removing Air-Cooled Contact Tip Adapter	37
11-6.	Removing Water-Cooled Contact Tip Adapter	37
11-7. Error Displays		38
11-8.	Using Self Test	39
11-9.	Troubleshooting	40
SECTION 12 − ELECTRICAL DIAGRAM		42
SECTION 13 − PARTS LIST		46
OPTIONS AND ACCESSORIES
WARRANTY

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Contents Processes OM-1589Description From Miller to You Table of Contents 10-1 10-211-1 11-2Standards DirectivesDeccon 11/96 Page Symbol Usage Marks a special safety messageArc Welding Hazards Electric Shock can killARC Rays can burn eyes and skin Welding can cause fire or explo- sionFlying Metal can injure eyes Buildup of GAS can injure or killPrincipal Safety Standards EMF Information About PacemakersSignification des symboles − Consignes DE Securite − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un incendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent pro- voquer des brûlures graves LE Bruit peut affecter l’ouïeRisque D’INCENDIE OU LA Chute DE L’APPAREIL peut blesser’EMPLOI Excessif peut DES Organes Mobiles peuvent provoquer des blessuresInformation sur les champs électromagnétiques Principales normes de sécuritéConsignes relatives aux stimulateurs cardiaques Disconnect input plug or power before working on machine − DefinitionsDrive rolls can injure fingers Keep your head out of the fumesSymbols And Definitions Manufacturer’s Rating Label for CE Products− Installation SpecificationsType of Input Welding Power Wire Feed Welding Overall WeightTypical Water-Cooled System Connections Tools Needed 16, 5/8, 11/16, 3/4Pin Plug Information Rear Panel ConnectionsPin Pin Information Internal Connections for Water-Cooled Gun Internal Connections for Air-Cooled GunTions directly to gun hose To gun partsFront Panel Connections for Gun Tools Needed 11/16, 1-1/8 Water-Cooled Model ShownWater-Cooled Guns Air-Cooled GunAdjusting Contact Tip Position Setting Torque SwitchTorque Switch Removing Top Cover of GunInstalling Wire Spool Wire Spool Top Cover Pressure Roll Assembly Gun Contact TipThreading Welding Wire Through Feeder Hub Tension AdjustmentCally live when gun Wire150 mm Open tension arm 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 Pair− Using the Optional Data Card Dual Schedule Switch DiagramsData Card Terms AdapterInstalling Data Card Wire feeder memoryCard Displays 3 seconds and the 8 programsSystem Setup Display Parameters − System SetupDisplay Setting Program 1 − Aluminum − Standard Pulse Welding ProgramsProgram 2 − Aluminum Program 3 − Aluminum Program 4 − AluminumGas 100% Argon / 20-Max CFH 24.5 435 325Program 5 − Aluminum Program 6 − Aluminum23.2 490 290 Gas 100% Argon / 20-45 CFHProgram 8 Aluminum Program 7 − Aluminum875 485 140 250 31.5 820 470 135 240 30.9 765 450 21.2 160 305 19.6 105 300 22.2− Teach Points Teach Points ExplainedRedefining IPM Teach Point Redefining Teach PointsRedefining Pulse Parameters Date Program Number Wire Size/Type Serial Number Wire FeederFlowrate CFHL/min Positive− Maintenance and Troubleshooting Routine MaintenanceFeeder Drive Assembly Maintenance Disconnect power before maintainingGun Drive Assembly Maintenance Changing Gun Contact Tip and LinerRemoving Air-Cooled Contact Tip Adapter Removing Water-Cooled Contact Tip AdapterBarrel Extension Remove as shownRelease Trigger Error Display Error DisplaysNo Volt Sensed Error Display Using Self Test E s s OM-1589Troubleshooting Disconnect power before troubleshootingFilter, and clean fittings 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 Service Your distributor also givesSupport Step of the wayMiller Electric Mfg. Co To locate distributor nearest you call 1-800-4-A-Miller

TABLE OF CONTENTS

SECTION 9 − STANDARD PULSE WELDING PROGRAMS

10-1.

10-2.

11-1.

11-2.

11-3.

11-5.

11-6.

11-8.

11-9.