Miller Electric OM-1589 manual Error Displays, Release Trigger Error Display

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11-7. Error Displays

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1 Release Trigger Error Display

This appears if the trigger is closed when the unit power is turned on, or if the trigger is stuck or defective.

2 No Volt Sensed Error Display

The arc voltage sense circuit is not receiving feedback. Check voltage sensing connections. Check con- nections at 17-position plugs/re- ceptacles at the unit and welding power source.

Turn unit off and back on after cor- recting problem.

If this error continues to occur when pulse welding, it may help to select Hot Start.

3 Memory CRC Error Display

The data in the program indicated is not the same data that was saved.

Perform a system reset.

4 Memory Range Error Display

The data in the program indicated is out of usable range.

Go through pulse parameters to make sure they do not exceed set- tings of the Range display or per- form a system reset.

5 No Tach Sensed Error Display

The motor tach feedback is not reaching the control. Check con- nections.

Press front panel Parameter Select to clear error.

6 Arc Start Error Display

This appears when pulse welding and current is detected but the arc cannot be started. Check and cor- rect program pulse parameters and voltage settings. Check voltage sensing connections.

Press front panel Parameter Select to clear error.

7 Arc Stop Error Display

This appears when pulse welding and the motor does not stop at the end of the weld. If there is high fre- quency being used in the area, turn it off. A motor brake circuit problem can also cause this error.

Press front panel Parameter Select to clear error.

8 Minimum Gas Flow Error

This appears when gas flow falls below the minimum CFH set (xx in example). Adjust gas flow to bring it above set value.

Press front panel Parameter Select to clear error.

9 Maximum Gas Flow Error

This appears when gas flow is above the maximum CFH set (xx in example). Adjust gas flow to bring it below set value.

Press front panel Parameter Select to clear error.

10 Gas Out Of Range Error

This appears when gas flow is greater than 100 CFH. To protect the internal sensor, the unit shuts down until the gas flow can be ad- justed below 100 CFH.

11 Coolant Flow Error

This appears when coolant flow is interrupted. Check coolant flow and coolant supply before continuing operation.

Ref. 800 687-A

OM-1589 Page 38

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Contents Description OM-1589Processes From Miller to You Table of Contents 10-1 10-211-1 11-2Deccon 11/96 DirectivesStandards 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 blessuresConsignes relatives aux stimulateurs cardiaques Principales normes de sécuritéInformation sur les champs électromagnétiques 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 Pin Information Rear Panel ConnectionsPin Plug 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-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 Pair− Using the Optional Data Card Dual Schedule Switch DiagramsData Card Terms AdapterInstalling Data Card Wire feeder memoryCard Displays 3 seconds and the 8 programsDisplay Setting − System SetupSystem Setup Display Parameters Program 2 − Aluminum − Standard Pulse Welding ProgramsProgram 1 − 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 Pulse Parameters Redefining Teach PointsRedefining IPM Teach Point 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 shownNo Volt Sensed Error Display Error DisplaysRelease Trigger 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