Miller Electric OM-1589 manual

XR-M W ire Feeder XR-M Air- And W ater-Cool ed Guns Processes Description  MIG (GMA W) Welding Pulsed MIG (GMAW - P) Wire Feeder And Feeder Gun OM-1589 163 473F June 1999  Visit our website at www.MillerWelds.com[...]

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. T o locate your nearest distributor call 1-800-4-A-Miller . Thank you and congratulations on choosing Miller [...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . [...]

T ABLE OF CONTENTS SECTION 8 − SYSTEM SETUP 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. System Setup Display Parameters 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 − ST ANDARD PULSE WELDING PROGRAMS 28 .[...]

dec_con 1 1/96 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Note Manufacturer ’ s Name: Miller Electric Mfg. Co. Manufacturer ’ s Address: 1635 W . Spencer Street Appleton, WI 54914 USA Declares that the product: XR  -M conforms to the [...]

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OM-1589 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! W atch[...]

OM-1589 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly of f from the weld. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z[...]

OM-1589 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. F [...]

OM-1589 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However , after examining more than 500 studies spanning 17 years [...]

OM-1589 Page 5 SECTION 1 − CONSIGNES DE SECURITE − LIRE A V ANT UTILISA TION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier . . Signif[...]

OM-1589 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS DE L ’ARC peuvent pro- voquer des brûlures dans les yeux et sur la[...]

OM-1589 Page 7 1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. D Ne pas placer l’appareil sur , au-dessus ou à proxi- mité de surfaces infllammables. D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installati[...]

OM-1589 Page 8 1-4. Principales normes de sécurité Safety in W elding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society , 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, W ashington, D.C. 20402. Recommended Safe Practice for the Prep[...]

OM-1589 Page 9 SECTION 2 − DEFINITIONS 2-1. W arning Label Definitions A.. W arning! Watch Out! There are possible hazards as shown by the symbols. B.. Drive rolls can injure fingers C.. Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects clear . 1 Electric shock can kill. 1.1 W ear dry insulating[...]

OM-1589 Page 10 2-2. Manufacturer ’ s Rating Label for CE Products 178 794-A For label location see Section 3-4. S/N: 24 3.0 Hz 50/60 IP 23 V 100 A 400 X 100 % MILLER ELECTRIC MFG. CO., APPLETON, WI USA V U 1 = A I 1 = 1 U 2 = I 2 = 2-3. Symbols And Definitions Some symbols are found only on CE products. NOTE Output Alternating Current A Amperes [...]

OM-1589 Page 1 1 SECTION 3 − INST ALLA TION 3-1. Specifications T y pe of Input Power W elding Power Source T y pe Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating IP Rating Overall Dimensions W eight 24 V olts AC Single-Phase 3 Amperes 50/60 Hertz Constant V oltage (CV) DC For GMAW Or Constant V oltage(CV) / Constant Current (CC[...]

OM-1589 Page 12 3-3. T ypical W ater-Cooled System Connections 801 810 / Ref. 175 086 / Ref. 180 31 1-B 1 300/400 Ampere Model CC/CV Inverter W elding Power Source . Use settings shown for both pulse MIG welding and MIG welding. 2 450 Ampere Model CV Inverter Welding Power Source System can be set up with a variety of conventional Constant V oltage[...]

OM-1589 Page 13 3-4. Rear Panel Connections Ref. 800 689 1 Rating Label Location 2 Coolant Supply Hose Route supply hose and connect to rear of Water T o Gun fitting in feeder . 3 Weld Cable If using conventional welding power source, route through reed relay in feeder . Connect to power block. 4 Coolant Return Hose Route return hose and connect to[...]

OM-1589 Page 14 3-6. Internal Connections for W ater-Cooled Gun Ref. 800 688-B 1 Wire C o n duit 2 Thumbscrew 3 Wire Conduit Block Loosen thumbscrew and insert conduit into block. Tigh ten thumb- screw . T ighten strain relief. 4 Power Block Weld Cable Connection 5 W eld/W ater From Gun Fitting Y If using a recirculating cool- ant system, make conn[...]

OM-1589 Page 15 3-8. Front Panel Connections for Gun Ref. 800 688-B T ools N e e d e d : 5/8, 1 1/16, 1-1/8 in W ater-Cooled Guns: 1 Gun Control Cable Insert plug into Gun Control receptacle, and tighten threaded collar . 2 Gas Hose Connect to Gas fitting on feeder . 3 Power/W ater Cable 4 Strain Relief Remove strain relief as shown. Route cable th[...]

OM-1589 Page 16 3-9. Removing T op Cover of Gun 800 942 1 T op Cover Push back and lift off as shown. T o reinstall cover , set rear of cover in gun, and push cover back, down, and forward until it clicks into posi- tion. 1 3-10. Adjusting Contact Tip Position Ref. 150 434 / Ref. 150 431 1 Contact Tip 2 Nozzle Adjusting barrel changes contact tip l[...]

OM-1589 Page 17 3-12. Installing Wire Spool 800 690-A / 800 945 1 Wire Spool 2 T op Cover 3 Pressure Roll Assembly 4 Gun Contact Tip If wire spool is being replaced, open pressure roll assembly in gun, and cut welding wire off at contact tip. Retract wire onto spool. 5 Hub 6 Hub Pin 7 Compression Spring (Optional For 8 in Spool) 8 Retaining Ring In[...]

OM-1589 Page 18 3-13. Threading W elding Wire Through Feeder Ref. 800 945 / 800 690-A 1 Wire Spool Location 2 T ension Arm 3 Mounting Arm 4 Wire Inlet Guide 5 Feeder Drive Roll 6 Wire Conduit 7 T ension Thumbnut 8 Jog Button 9 Pressure Roll Assembly 10 Gun Drive Roll Fo r wire sizes .035 in (0.9 mm) and smaller use small groove, and .047 in (1.2 mm[...]

OM-1589 Page 19 3-14. Threading Welding Wire Through Feeder (Continued) Ref. 800 944 T ools N e e d e d : Pull and hold wire; cut off end. Hold wire tightly to keep it from unraveling. 6 in (150 mm) Open tension arm. Thread wire thru inlet guide, along drive roll groove, and into wire con- duit. Close tension arm. Adjust tension as follows: grasp s[...]

OM-1589 Page 20 SECTION 4 − OPERA TION 4-1. Operational T erms See Menu Guide for detailed programming steps. NOTE The following is a list of terms and their definitions as they apply to this wire feeder: General T erms: Adaptive Pulse W elding The wire feeder automatically regulates pulse frequency to maintain a constant arc length, regardless o[...]

OM-1589 Page 21 4-3. Front Panel Controls 800 687-A 1 Display 2 Parameter Select Button Press button to move > on display . 3 Display Control Knob Tur n knob to change parameter pointed to by > . T urning knob one click causes Trim (arc length) to increase/decrease by one or V olt to increase/decrease by 0.1. When IPM is selected, turning kno[...]

OM-1589 Page 22 4-4. Side and Rear Panel Controls Ref. 800 690-A / Ref. 800 869 1 Mode Display 2 Data Card Slot 3 Parameter Display 4 Parameter Increase Button 5 Parameter Decrease Button 6 Parameter Select Button Press button to move > in display . 7 Optional Gas Flow Adjustment Knob Allows accurately presetting gas flow rate on wire feeder fro[...]

OM-1589 Page 23 SECTION 5 − SETTING SEQUENCE P ARAMETERS 5-1. Sequence Parameters in a Program . See Menu Guide for detailed programming steps. Trim is arc length. If set to zero, arc length is short. If set to 99, arc length is long. If time is set to zero in Weld se- quence, welding continues until gun trigger is released. . Crater and Burnback[...]

OM-1589 Page 24 SECTION 6 − SETTING DUAL SCHEDULE P ARAMETERS 6-1. Selecting Dual Schedule Pair Dual Schedule is used with two consecutive weld programs 1 & 2, 3 & 4, 5 & 6, or 7 & 8. Any program type (MIG, Adaptive Pulse, or Pulse) can be combined in dual schedule. 1 Side Panel Display Use side panel to turn feature on. See Menu [...]

OM-1589 Page 25 6-2. Dual Schedule Switch Diagrams 1 Momen 2P (Momentary-Contact 2-Pole Switch or DSS-10) 2 Maint 2P (Maintained-Contact 2-Pole Switch) 3 Maint 1P (Maintained-Contact 1-Pole Switch, Or DSS-8) 4 T rigger Allows dual scheduling after estab- lishing a welding arc. . If trigger is used for dual sched- ule switch, T rigger Hold is dis- a[...]

OM-1589 Page 26 7-2. Installing Data Card 156 266-B 1 Label Apply label to data card. W rite pro- gram information on label. 2 Data Card 3 Card Slot For Blank Data Card: Insert card into slot. T o format card, turn On power . Select Card from menu. Data card formats when unit enters Card mode. For Power Source Data Card: Insert card into slot. T ur[...]

OM-1589 Page 27 SECTION 8 − SYSTEM SETUP 8-1. System Setup Display Parameters See Menu Guide for detailed programming steps. NOTE Display Setting Notes >System * Select the process the welding power source is able to do. >Range * W elding power source minimum and maximum voltage values are always needed. Amperage values are required for pul[...]

OM-1589 Page 28 SECTION 9 − ST ANDARD PULSE WELDING PROGRAMS Apk = Peak Amperage, Abk = Background Amperage, PPS = Pulses Per Second, PWms = Pulse Width (milliseconds). NOTE 9-1. Program 1 − Aluminum Wire Size/T ype: .030” ER 4043 Gas: 100% Argon / 15-80 CFH Gun Model: 30 Ft W ater-Cooled IPM / MPM Apk Abk PPS PWms V olts COMMENTS 875 360 90 [...]

OM-1589 Page 29 9-3. Program 3 − Aluminum Wire Size/T ype: 3/64” ER 4043 Gas: 100% Argon / 20-Max CFH Gun Model: 30 Ft W ater-Cooled IPM / MPM Apk Abk PPS PWms V olts COMMENTS 875 500 195 270 3.0 30.5 820 480 185 270 3.0 29.4 765 460 175 270 3.0 29.0 710 440 160 260 2.8 28.5 655 420 150 255 2.7 27.8 600 400 140 250 2.6 27.3 545 380 130 239 2.5 [...]

OM-1589 Page 30 9-5. Program 5 − Aluminum Wire Size/T ype: .030” ER 5356 Gas: 100% Argon / 20-40 CFH Gun Model: 30 Ft W ater-Cooled IPM / MPM Apk Abk PPS PWms V olts COMMENTS 875 340 78 144 2.4 25.0 820 335 73 140 2.3 24.4 765 330 70 138 2.2 24.1 710 325 67 133 2.1 23.3 655 320 62 128 2.0 23.1 600 310 59 123 1.9 23.2 545 300 55 11 7 1.8 23.2 49[...]

OM-1589 Page 31 9-7. Program 7 − Aluminum Wire Size/T ype: 3/64” ER 5356 Gas: 100% Argon / 20-Max CFH Gun Model: 30 Ft W ater-Cooled IPM / MPM Apk Abk PPS PWms V olts COMMENTS 875 485 140 250 3.0 31.5 820 470 135 240 2.9 30.9 765 450 11 7 235 2.8 29.0 710 433 107 230 2.7 27.6 655 410 100 220 2.6 26.4 600 395 89 207 2.5 25.6 545 380 84 197 2.5 2[...]

OM-1589 Page 32 SECTION 10 − TEACH POINTS 10-1. T each Points Explained 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. The five parameters are: IPM (MPM), Apk, Abk, PPS, and PWms. Apk, Abk[...]

OM-1589 Page 33 10-2. Redefining T each Points Ref. S-0259 / Ref. 154 109 1 IPM IPM determines the weld metal de- position rate. . Redefining IPM is not normally required unless special wire or unusual joint design is needed. Use front panel parameter select button to move > to select IPM. Use Display Control to select teach point value. Press a[...]

OM-1589 Page 34 Date Program Number Wire Size/T ype Gas Flowrate CFH(L/min) Equipment Used − Power Source Serial Number Wire Feeder Serial Number Gun Model Weld Cable − Negative Positive Wire Manufacturer Mfg. Date IPM / MPM Apk Abk PPS PWms Vpk COMMENTS Preflow Seconds: Run-In T rim/V olts: IPM / MPM: Seconds: Crater V olts: IPM / MPM: Seconds[...]

OM-1589 Page 35 SECTION 1 1 − MAINTENANCE AND TROUBLESHOOTING 1 1-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Unreadable Labels Clean And T ighten W eld T erminals Repair Or Replace Cracked W eld Cable 14-Pin Cord Gas Hose And Fittings Gun Cable Replace Cracked Parts 6 Months Blow Out Or V acuum Inside. During H[...]

OM-1589 Page 36 1 1-3. Changing Gun Contact Tip and Liner 150 437 T ools N e e d e d : Remove top cover and open pressure roll assembly . 1 Contact Tip W rench Insert wrench into nozzle over contact tip. 2 Compression Nut Loosen nut. Pull out contact tip. 3 Contact Tip 4 Nozzle Pull wire out nozzle and liner should slide out. If necessary , tilt no[...]

OM-1589 Page 37 1 1-5. Removing Air-Cooled Contact Tip Adapter 150 430-A 1 Barrel Extension Remove as shown. 2 Contact Tip 3 Compression Nut T o remove, see Section 1 1 -3. 4 Contact Tip Adapter 5 Head Tube 6 Head T ube Setscrew Loosen setscrews and remove adapter . Install new a d a p t e r and tighten set- screws. Reinstall contact tip, com- pres[...]

OM-1589 Page 38 1 1-7. Error Displays Ref. 800 687-A 1 Release T rigger 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 V olt Sensed Error Display The arc voltage sense circuit is not receiving feedback. Check v oltage sensing connections. Check con- nections at 17-[...]

OM-1589 Page 39 1 1-8. Using Self T est Y Have only Factory-Autho- rized persons perform tests or replace parts. 1 Switch A This checks the gun switch in- crease position. 2 Switch B This checks the gun switch de- crease position. 3 T rigger This checks the gun trigger . 4 Wire Feed This checks the wire feed motor . 5 Gas This checks the gas valve.[...]

OM-1589 Page 40 1 1-9. T roubleshooting Y Disconnect power before troubleshooting. T rouble Remedy Pressing gun trigger does not energize feeder . Welding wire is not energized. Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 3-8). feeder . Welding wire is not energized. Shielding gas does not flow . Have neare[...]

OM-1589 Page 41 Notes[...]

OM-1589 Page 42 SECTION 12 − ELECTRICAL DIAGRAM Figure 12-1. Circuit Diagram[...]

OM-1589 Page 43 184 771-A[...]

OM-1589 Page 44 Figure 12-2. Circuit Diagram For Gun 163 699[...]

OM-1589 Page 45 Notes[...]

OM-1589 Page 46 SECTION 13 − P ARTS LIST 800 959-A 77 35 40 72 26 27 28 29 30 63 47 35 23 5 6 7 8 10 11 13 12 1 2 3 4 14 16 15 17 18 19 20 21 22 25 43 44 45 74 36 58 57 3 2 33 34* 49 48 50 46 51 61 62 60 64 59 58 57 56 9 8 2 81 80 Fig 13-2 Fig 13-3 73 71 70 75 76 67 43 79 78 69 68 67 66 65 55 42 41 39 37 38 24 53 54 55 31 25 *Includes Items 37 Th[...]

OM-1589 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly Quanti ty 1 178 936 LABEL, warning general precautionary 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 +169 085 WRAPPER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-1589 Page 48 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quanti ty 52 PC80 182 299 CIRCUIT CARD, HF filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG81 1 15 093 CONNECTOR & SOCKETS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-1589 Page 49 1 14 188-F 23 4 5 6 7 9 10 11 20 13 14 15 16 17 18 19 13 12 12 21 22 23 24 8 1* 3 *Includes Items 15-18 . Hardware is common and not available unless listed. Figure 13-2. Motor & Wire Drive Description Part No. Dia. Mkgs. Item No. Figure 13-2. Motor & Wire Drive (Fig 13-1 Item 80) Quanti ty 1 1 15 191 DRIVE ASSEMBL Y , wire [...]

OM-1589 Page 50 Item 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 800 960 See Fig 13-1 . Hardware is common and not available unless listed. PC20 Figure 13-3. Panel, Front w/Components Description Part No. Dia. Mkgs. Item No. Figure 13-3. Panel, Front w/Components (Fig 13-1 Item 73) Quanti ty 1 ♦ 164 964 FITTING, mtg switch flow 1 . .[...]

OM-1589 Page 51 1 2 3 4 5 6 7 8 800 1 13-B . Hardware is common and not available unless listed. PC60 PC40 Figure 13-4. Panel, Side w/Components Description Part No. Dia. Mkgs. Item No. Figure 13-4. Panel, Side w/Components (Fig 13-1 Item 16) Quanti ty 1 147 139 T APE, adh acrylic double sided .010 x .500 x 3.000 2 . . . . . . . . . . . . . . . . .[...]

OM-1589 Page 52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 7 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 800 434-A 3 5 19 . Hardware is common and not available unless listed. Figure 13-5. Barrel Assembly Description Part No. Dia. Mkgs. Item No. Figure 13-5. Barrel Assembly (Fig 13-6 Item 48) Quanti ty 1 144 862 EXTENSION, nozzle (XRM-1[...]

OM-1589 Page 53 Description Part No. Dia. Mkgs. Item No. Figure 13-5. Barrel Assembly (Fig 13-6 Item 48) (Continued) Quanti ty 17 137 042 BARREL ASSEMBL Y , water cooled (XRM-15W & 30W models) . . . . . . . . . . . . . . . . (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-1589 Page 54 801 000-C *Includes Item 36 . Hardware is common and not available unless listed. 48(Fig. 13−5) 55 59 57 58 56 53 1 61 60 62 2 52 8 3 4 5 6 6 7 9 10 11 12 13 14 15 13 16 17 18 63 20 19 21 22 23 64 23 65 24 25 26 27 28 29 30 32 33 34 35 31* 36 37 38 39 40 41 42 43 44 45 46 41 47 49 50 51 54 Figure 13-6. XRM-A & W Guns[...]

OM-1589 Page 55 Description Part No. Dia. Mkgs. Item No. Figure 13-6. XRM-A & W Guns Quanti ty 1 133 479 COVER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 135 196 SPRING, closure cover 1 . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-1589 Page 56 Description Part No. Dia. Mkgs. Item No. Figure 13-6. XRM-A & W Guns (Continued) Quanti ty 48 Fig 13-5 BARREL ASSEMBL Y 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 137 495 FITTING, connection power weld (XRM-15A & 30A models) 1 . . . . . . . .[...]

Warranty Questions? Call 1-8 00-4-A-M ILLE R for your local Miller distrib u t o r. miller_warr 1/99 Y our distributor also gives you ... Service Y ou 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 expe[...]

PRINTED IN USA  1999 Miller Electric Mfg. Co. 9/98 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 West Spenc er S treet Applet on, W I 54914 US A International He adquarte rs− USA USA Phone: 920-735-4505 Aut o-A t t ended USA & C anada F AX: 9 20-735-4134 Int ernati onal FAX: 920-735-4125 European H e a dquart ers − [...]