Miller Electric OM-1589 manual Your distributor also gives, Service, Support, Step of the way

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Warranty Questions?

Call

1-800-4-A-MILLER

for your local

Effective January 1, 1999 (Equipment with a serial number preface of “KK” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

Miller distributor.

Your distributor also gives

you ...

Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor.

The expertise of the distributor and Miller is there to help you, every

LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor.

1.5 Years Parts − 3 Years Labor

*Original main power rectifiers

*APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches

*Remote Controls

*Accessory Kits

*Replacement Parts (No labor)

*Spoolmate 185

Miller’s True BlueLimited Warranty shall not apply to:

1.Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

2.Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear.

3.Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

step of the way.

*Inverters (input and output rectifiers only)

2.3 Years — Parts and Labor

*Transformer/Rectifier Power Sources

*Plasma Arc Cutting Power Sources

*Semi-Automatic and Automatic Wire Feeders

*Inverter Power Supplies

*Intellitig

*Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

3.1 Year — Parts and Labor

*Motor Driven Guns (w/exception of Spoolmate 185)

*Process Controllers

*Positioners and Controllers

*Automatic Motion Devices

*Robots

*IHPS Power Sources

*Water Coolant Systems

*HF Units

*Grids

*Spot Welders

*Load Banks

*SDX Transformers

*Miller Cyclomatic Equipment

*Running Gear/Trailers

*Plasma Cutting Torches (except APT, ZIPCUT & PLAZCUT Models)

*Deutz Engines (outside North America)

*Field Options

(NOTE: Field options are covered under True Bluefor the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

4.6 Months — Batteries

5.90 Days — Parts

*MIG Guns/TIG Torches

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

miller_warr 1/99

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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