Related Manuals for Miller Electric OM-1589
Summary of Contents for Miller Electric OM-1589
- Page 1 XR-M Air- And Water-Cooled Guns Visit our website at www.MillerWelds.com OM-1589 June 1999 Processes Description Wire Feeder And Feeder Gun XR-M Wire Feeder 163 473F MIG (GMAW) Welding Pulsed MIG (GMAW-P)
- Page 2 ISO 9001 Quality service information for your particular model System Standard. are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.
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Page 3: Table Of Contents
7-2. Installing Data Card 7-3. Card Displays OM-1589 TABLE OF CONTENTS .............. - Page 4 TABLE OF CONTENTS SECTION 8 − SYSTEM SETUP ............8-1.
- Page 5 Declaration of Conformity for European Community (CE) Products Note This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA XR -M...
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Page 7: Section 1 − Safety Precautions - Read Before Using
The coatings and any metals containing these elements can give off toxic fumes if welded. som _nd_5/97 OM-1589 Page 1... - Page 8 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
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Page 9: Additional Symbols For Installation, Operation, And Maintenance
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. OM-1589 Page 3... -
Page 10: Emf Information
To reduce magnetic fields in the workplace, use the following procedures: OM-1589 Page 4 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. -
Page 11: Signification Des Symboles
été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. som _nd_fre 5/97 OM-1589 Page 5... - Page 12 Pendant la période de refroidissement des soudures, elles ris- quent de projeter du laitier. D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. OM-1589 Page 6 LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou même la mort.
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Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
D Porteurs de stimulateur cardiaque, restez à dis- tance. D Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’appro- cher des opérations de soudage à l’arc, de gou- geage ou de soudage par points. OM-1589 Page 7... -
Page 14: Principales Normes De Sécurité
établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnéti- ques pendant le soudage ou le coupage. OM-1589 Page 8 Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. -
Page 15: Section 2 − Definitions
Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. Become trained and read the instructions before working on the machine or welding. Do not remove or paint over (cover) the label. OM-1589 Page 9... -
Page 16: Manufacturer's Rating Label For Ce Products
Indicator Light Primary Current Wire Feed Single Phase OM-1589 Page 10 S/N: 50/60 IP 23 X 100 % MILLER ELECTRIC MFG. CO., APPLETON, WI USA Alternating Current Duty Cycle Parameter Select Read Instructions Trigger Hold Off Indicator Light Rated Welding Current... -
Page 17: Section 3 − Installation
50 psi (345 kPa) or me- chanical gas valve in gun can leak. 10 Gas Hose 11 Gas Cylinder Route hose from regulator/flowme- ter and connect to shielding gas valve fitting. 801 809 / Ref. 175 086 / Ref. 180 311-B OM-1589 Page 11... -
Page 18: Typical Water-Cooled System Connections
3-3. Typical Water-Cooled System Connections Tools Needed: 9/16, 5/8, 11/16, 3/4 in OM-1589 Page 12 300/400 Ampere Model CC/CV Inverter Welding Power Source Use settings shown for both pulse MIG welding and MIG welding. 450 Ampere Model CV Inverter Welding Power... -
Page 19: Rear Panel Connections
Connect to power block. Coolant Return Hose Route return hose and connect to rear of Weld/Water From Gun fitting or optional flow switch in feeder. Gas Hose 14-Pin Plug Ref. 800 689 OM-1589 Page 13... -
Page 20: Internal Connections For Water-Cooled Gun
3-6. Internal Connections for Water-Cooled Gun Tools Needed: 9/16, 11/16 in 3-7. Internal Connections for Air-Cooled Gun Tools Needed: 9/16 in OM-1589 Page 14 Wire Conduit Thumbscrew Wire Conduit Block Loosen thumbscrew and insert conduit into block. Tighten thumb- screw. Tighten strain relief. -
Page 21: Front Panel Connections For Gun
Connect to Gas fitting on feeder. Power Cable Route cable through front panel and connect to power block. See Section 3-7. Strain Relief Remove strain relief as shown. Wire Conduit Route through strain relief. Insert through front panel. Go to Section 3-7. OM-1589 Page 15... -
Page 22: Removing Top Cover Of Gun
3-9. Removing Top Cover of Gun 3-10. Adjusting Contact Tip Position Water-Cooled Model 3-11. Setting Torque Switch OM-1589 Page 16 Air-Cooled Model Top Cover Push back and lift off as shown. To reinstall cover, set rear of cover in gun, and push cover back, down, and forward until it clicks into posi- tion. -
Page 23: Installing Wire Spool
If wire spool is being replaced, open pressure roll assembly in gun, and cut welding wire off at contact tip. Retract wire onto spool. Hub Pin Compression Spring (Optional For 8 in Spool) Retaining Ring Install wire spool. 800 690-A / 800 945 OM-1589 Page 17... -
Page 24: Threading Welding Wire Through Feeder
3-13. Threading Welding Wire Through Feeder Tools Needed: OM-1589 Page 18 Wire Spool Location Tension Arm Mounting Arm Wire Inlet Guide Feeder Drive Roll Wire Conduit Tension Thumbnut Jog Button Pressure Roll Assembly 10 Gun Drive Roll For wire sizes .035 in (0.9 mm) and smaller use small groove, and .047 in (1.2 mm) and 1/16 in... -
Page 25: Threading Welding Wire Through Feeder (Continued)
Cut off wire. Reinstall gun cover. Close sure. If necessary, adjust pres- sure adjustment knob in gun. Welding wire is electri- cally live when gun trigger is used to jog wire. and latch wire feeder doors. Ref. 800 944 OM-1589 Page 19... -
Page 26: Section 4 − Operation
Sequence Mode Is used to select and program the weld sequences which include weld, crater, burnback, postflow, preflow, and run-in. 4-2. Pulse Welding Terms Amps OM-1589 Page 20 Apk = Peak Amperage Increasing Apk increases penetra- tion. Abk = Background Amperage Maintains arc between pulses. -
Page 27: Front Panel Controls
If gun trigger is not released within the first three seconds after arc initiation, trigger hold stops, but is still active for next weld cycle. To end weld cycle, press and release gun trig- ger. OM-1589 Page 21... -
Page 28: Side And Rear Panel Controls
4-4. Side and Rear Panel Controls 4-5. Gun Controls OM-1589 Page 22 Mode Display Data Card Slot Parameter Display Parameter Increase Button Parameter Decrease Button Parameter Select Button Press button to move > in display. Optional Gas Flow Adjustment Knob... -
Page 29: Section 5 − Setting Sequence Parameters
Crater and Burnback do not function in Pulse or Adaptive Pulse. If time is set to zero in any timed se- quence except Weld, the sequence is skipped. Burnback Time Postflow Time Time Sequence Seconds 0-25.0 0-2.50 0-0.025 0-9.9 0-2.50 0-5.00 OM-1589 Page 23... -
Page 30: Section 6 − Setting Dual Schedule Parameters
S e q u e n c e > D u a l S chd C a r d 2 4 . 0 V 2 5 0 I P M OM-1589 Page 24 1 & 2 > P r g D u a l Display Control >... -
Page 31: Dual Schedule Switch Diagrams
Allows dual scheduling after estab- lishing a welding arc. If trigger is used for dual sched- ule switch, Trigger Hold is dis- abled. R e a d D e l e t e D o n e OM-1589 Page 25 158 435... -
Page 32: Installing Data Card
>C a r d >W r i t e R e a d D e l e t e D o n e OM-1589 Page 26 P r e s s B e l o w Side Panel Parameter Select Once P u l s e 0 3 5 ”... -
Page 33: Section 8 − System Setup
Can be used only when optional data card is inserted. ** Selection does not appear on display when MIG Only is System choice. Must remain set to Meter Off if option is not installed to prevent system error. OM-1589 Page 27... -
Page 34: Section 9 − Standard Pulse Welding Programs
Wire Size/Type: .030” ER 4043 IPM / MPM 9-2. Program 2 − Aluminum Wire Size/Type: .035” ER 4043 IPM / MPM OM-1589 Page 28 Gas: 100% Argon / 15-80 CFH PWms Gas: 100% Argon / 20-40 CFH PWms Gun Model: 30 Ft Water-Cooled... -
Page 35: Program 3 − Aluminum
30.5 29.4 29.0 28.5 27.8 27.3 26.7 24.5 23.9 22.9 22.3 22.0 21.8 19.6 20.3 Gun Model: 30 Ft Water-Cooled Volts COMMENTS 32.0 32.0 32.0 32.0 31.9 31.5 31.0 28.0 29.5 25.4 24.4 23.4 22.9 20.1 22.0 OM-1589 Page 29... -
Page 36: Program 5 − Aluminum
Wire Size/Type: .030” ER 5356 IPM / MPM 9-6. Program 6 − Aluminum Wire Size/Type: .035” ER 5356 IPM / MPM OM-1589 Page 30 Gas: 100% Argon / 20-40 CFH PWms Gas: 100% Argon / 20-45 CFH PWms Gun Model: 30 Ft Water-Cooled... -
Page 37: Program 7 − Aluminum
31.5 30.9 29.0 27.6 26.4 25.6 25.5 24.6 24.9 24.4 23.5 22.6 21.2 19.6 22.2 Gun Model: 30 Ft Water-Cooled Volts COMMENTS 33.0 33.0 33.0 33.0 31.0 29.1 27.4 25.5 22.3 23.7 24.3 21.8 22.9 19.4 19.9 OM-1589 Page 31... -
Page 38: Section 10 − Teach Points
Abk = Background Amperage PPS = Pulses Per Second PWms = Pulse Width (Milliseconds) PWms OM-1589 Page 32 The teach mode allows the user to create custom pulse programs. The teach mode has 15 teach points. At each teach point, the user can ad- just five parameters to shape the pulse waveform of the weld output. -
Page 39: Redefining Teach Points
The taught arc length represents a Trim (arc length) setting of 50. Once the teach points are set, the wire feeder adjusts parameters be- tween teach points synergically. Ref. S-0259 / Ref. 154 109 OM-1589 Page 33... - Page 40 Gun Model Weld Cable − Negative Wire Manufacturer Mfg. Date IPM / MPM Preflow Seconds: Run-In Trim/Volts: IPM / MPM: Crater Volts: Postflow Seconds: OM-1589 Page 34 Wire Size/Type Flowrate PWms IPM / MPM: CFH(L/min) Serial Number Positive COMMENTS Seconds:...
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Page 41: Section 11 − Maintenance And Troubleshooting
Tighten set- screws. Wire Inlet Guide Pull guide toward rear of feeder to remove. Install new guide. Thread welding wire and adjust drive roll pressure, if necessary (see Sections 3-13 and 3-14). OM-1589 Page 35... -
Page 42: Changing Gun Contact Tip And Liner
Insert wrench into nozzle over contact tip. Compression Nut 11-4. Gun Drive Assembly Maintenance Tools Needed: 5/16 in OM-1589 Page 36 Loosen nut. Pull out contact tip. Contact Tip Nozzle Pull wire out nozzle and liner should slide out. If necessary, tilt nozzle down to remove liner. -
Page 43: Removing Air-Cooled Contact Tip Adapter
Wipe gun dry before putting it back together. Nozzle Nozzle Adapter Remove as shown. Contact Tip Adapter Use wrench to remove adapter. Coat new adapter with threadlock- ing compound (such as Loctite No. 242), and install. 150 431 OM-1589 Page 37... -
Page 44: Error Displays
E r r o r C o o l a n t F l o w E r r o r OM-1589 Page 38 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. -
Page 45: Using Self Test
Contactor This checks the welding power source contactor. Increase O f f Increase >G a s O f f P r e s s Side Panel Parameter Select Increase >G a s P r e s s OM-1589 Page 39... -
Page 46: Troubleshooting
Check and replace liner if necessary (see Section 11-3). Be sure coolant flowrate is at least 1 qt/min. overheating (water-cooled models). models). Corrosion buildup in gun decreasing coolant flowrate. Backflush coolant system, clean coolant system filter, and clean fittings. OM-1589 Page 40 Y Disconnect power before troubleshooting. Remedy... - Page 47 Notes OM-1589 Page 41...
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Page 48: Section 12 − Electrical Diagram
SECTION 12 − ELECTRICAL DIAGRAM Figure 12-1. Circuit Diagram OM-1589 Page 42... - Page 49 184 771-A OM-1589 Page 43...
- Page 50 163 699 Figure 12-2. Circuit Diagram For Gun OM-1589 Page 44...
- Page 51 Notes OM-1589 Page 45...
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Page 52: Section 13 − Parts List
SECTION 13 − PARTS LIST Hardware is common and not available unless listed. 800 959-A Figure 13-1. Main Assembly OM-1589 Page 46... - Page 53 ............OM-1589 Page 47 Quantity...
- Page 54 To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1589 Page 48 Description ..........
- Page 55 ..........OM-1589 Page 49 114 188-F...
- Page 56 Part of 166 130 Optional Water Flow Shut Down Switch. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1589 Page 50 See Fig 13-1 Item 19 Figure 13-3.
- Page 57 ..............OM-1589 Page 51 800 113-B...
- Page 58 ... . 135 128 SCREW, cap stl sch 6-32 x 1.000 (XRM-15W & 30W models) OM-1589 Page 52 Figure 13-5. Barrel Assembly Description ......... . .
- Page 59 ............OM-1589 Page 53...
- Page 60 Hardware is common and not available unless listed. 801 000-C Figure 13-6. XRM-A & W Guns OM-1589 Page 54...
- Page 61 ..............OM-1589 Page 55 Quantity...
- Page 62 To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1589 Page 56 Description ..........
- Page 63 Miller distributor. 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.
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Page 64: Options And Accessories
Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 1999 Miller Electric Mfg. Co. 9/98 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA &...