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Miller Electric S-74DX User's Manual

1. 1 DUK 200 153 Overlay Upper Front Panel 1 gt 204 762 Overlay Upper Front Panel CE Version 1 c O24 TE 200 693 Circuit Card Assy Switches 1 ju ass POZO 210559 Panel Card Display Micro 1 200 551 4 Enclosure Control 22 i e ds ig 1 134 201 Stand Off Support PC Card 6 200554 Enclosure Motor kae RC RU 1 010 494 Bushing Snap In 1 375 Id X 1 750 Mtg Hole 1 TE m 057 357 Bushing Snap In 937 Id X 1 125 Mtg Hole 1 ms 204 910 Cable Power Consisting Of 1 RU PPM 16035919 22 2 sun io ed ume et aee aae ipee Dad ns 11 5 Ft uu EE 199 041 2 2 Stran xe iude e qo or etd a eo deat 1 ee di mi A ETT 079 739 Conn Circ Cpc Clamp Str 1 18 PLG12 141162 Housing Plug Pins Service Kit 1 PEOS 115 093 Housing Plug Skts Service Kit
2. 24 SECTION 7 SETTING SEQUENCE PARAMETERS 25 7 1 Sequence Parameters In A Program 25 SECTION 8 SETTING DUAL SCHEDULE PARAMETERS 26 8 1 Optional Dual Schedule Switch Diagrams 26 SECTION 9 MAINTENANCE EE TRUSTEES FERRE FEE 26 9 71 Routine Maintenance 23 2 i ice abeo De Rae clue dne ee ete Sod en ded oso 26 ers rA EVE REEF RE d ee addat 27 SECTION 10 ELECTRICAL DIAGRAM x iria xh n et ee 28 SECTION TI PARTS Te e deve o 30 OPTIONS AND ACCESSORIES WARRANTY Declaration of Conformity for European Community CE Products Manufacturer European Contact Miller Electric Mg Co Mr Danilo Fedolfi 1635 W Spencer St Managing Director Appleton WI 54914 USA ITW Welding Products Italy S r l Phone 920 734 9821 Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 European Contact Signature Declares that the product S 4 DX conforms to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC Electromagnetic Compatibility EMC Directive 89 336 Machinery Directives 98 37 EEC 91 368 E
3. 1 PT POS 134 834 Hose Sae 187 Id X 410 Od Order By Ft 2Ft Lid and trees quu es 149 959 Fitting Brs Barbed M 3 16tbg X 312 24 1 si Dans Le 179 265 Adapter Gun Feeder 1 Toc Hm 108 940 Screw Stl Hexhd 250 20 X 750 4 604 538 Washer Flat Stl 312 1 E 151 437 Knob Plstc T 1 125 Lg X 312 18 X 1 500 1 151 290 Screw Mach 51 Hexwhd 10 32 X 500 2 Cc TC 179 277 Cover Drive Roll Consisting Of 1 TCU 196 956 Label Warning Electric Shock 1 BUND ITINERE 601 872 Nut Stl Hex Full Fnsh 375 16 1 ERR 602 213 Washer Lock Stl Split 375 1 ES PETERE 602243 Washer Flat Stl Std 375 1 EHE 601 966 Screw Stl Hexhd 375 16 X 1 250 1 Recommended Spare Parts 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 15
4. Visit our website at www MillerWelds com Miller OM 1500 9 207 749K 2006 05 Processes MIG GMAW Welding Flux Cored FCAW Welding Gas And Self Shielded Description Wire Feeder OWNER S MANUAL File MIG GMAW Q From Miller to You Thank you and congratulations on choosing Miller Now you get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 Ir BL El Her This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They boleu Ie ete jue ere ex e every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick Ios and easy With Miller you can count on years MI 00012000 of reliable service with proper ma
5. 1 hots 605 227 Nut 750 14 Knurled1 68dia 41h Nyl 1 UD rs QST 228 035 Valve 34VDC 1Way 750 14 Thd 2mm Orf 100PSI 1 POT 217 872 Circuit Card Assy Motor Control 1 kw dorso PCT 217 922 Circuit Card Assy Motor Control Low Speed Motor 1 TEC M ST 21 111 997 Switch Rocker Spst 10a 250 VAC On Off 1 200 559 Panel Front a eate esi epe rd 1 OM 1500 9 Page 32 Diagram No marking oe ah recu cuits os dens To UE 23 ACTS i ERR PLGO PLG11 61 PLGT 2 2 TREND PEGA s eee PLG7 27 eo PLG10 D noue Part No Description Quantity Figure 11 2 Control Box Figure 11 1 Item 21 Continued Switch Rocker Spdt 15a 12v On Of On 1 Nameplate ee oe d d No e e d d ud ede ert 1 Nameplate CE 1 Knob Encoder 1 670 Dia X 250 Id Push On W Spring 1 RCDE OKS SERVICE KID dca egal edu aee dinars 1 Housing Plug Skts Service Kit 1 Housing Plug Skts Service Kit 1 Housing Plug Pins Skts Service Kit 1 Housing Plug Pins Skts Ser
6. 2 242 oy eM Ay 20 lt RCE 2 E pE Ze que lt RC6 1 0 ee 71 d 5 O 0 Rc26 1 gt gt 1 m os FS1 JA he ORANGE ON lt lt pg ONE 1 O 951 lt zs gt 46 ne RC26 2 gt JE 46 PNK x OPTIONAL COOLANT 4 lt gt ip lt RC4 1 02 FLOW SWITCH 2 p 1 PUR WHT 4 6 gt B gt lt RC4 4 MOTOR BOARD RC1 PLG1 12 RC3 PLG3 RC10 5 77 77 RC4 PLG4 zd ge uaque Ls qu o cue lt RC4 3 RC5 PLG5 RC10 1 gt gt 15V 2 gt S2 PC20 RC6 PLG6 INTERFACE DISPLAY BOARD 6l PURGES 4 dog RC7 PLG7 RC10 4 gt RC21 PLG61 6g RED 2 68 os ES T RC27 PLG27 LOAK TEOR pae pr RCS 2 1 2 lt 74 gt 7 SL lt L RCS 1 6 TACH PC51 ircuit Diagram Figure 10 1 C SECTION 10 ELECTRICAL DIAGRAM E MM RC3 4 D ORANGE COMMON lt RC3 3 RC7 1 e RC27 1 FS COMMON 7 3 gt gt oon Fee RC27 5 bo 21 HF STUD lt lt RC15 SWITCH BOARD 14 PIN PLG12 BLAK RC11 1 gt RC21 1 RC11 2 p MEE M k RC21 2 lt IURE COM lt RC1 1 NAE RC11 5 gt Z32V COMMON lt RC21 5 B L RO3 5 Fe YELLOW LCURAENT FEEDBACK lt RC3 1 RC7 9 gt AFSV lt RC27 9 H lt GROWN VOLTAGE FEEDBACK lt lt RC3 6 7 10 gt XXV COMM
7. Process Select Process selection indicated by PROS in the upper display is set to either or TRIM in the lower display Each program can be se lected be be a MIG program indicated by VOLT or a pulsing program indicated by TRIM Range Locks Range locks are indicated by LOCK in the upper display for wire speed or LOCK in the lower display for voltage range In a MIG pro gram the voltage range lock ranges from O to 10 volts In a pulse program the trim range lock ranges from 0 to 100 The wire feed speed range lock ranges from 0 to 250 ipm Locks are program dependent and wire speed is inde pendent from voltage or trim Wire Feed Speed Units Wire feed speed setting indicated by WFS in the upper display is set to IPM inches per minute or MPM meters per minute This setting is independent of the program se lected OPT1 e f the Setup push button is pressed the unit allows OPT1 to be disabled or enabled The upper display shows OPT1 Lower dis play shows On or Off The Adjust Control is used to select either On or Off OPT1 is used by the Water Flow Shutdown Option to stop the weld sequence if water flow to a water cooled gun is interrupted A closed set of contacts between pins 1 and 2 of RC26 on Interface Board PC20 will allow feeder to operate normally Opening the contacts will stop the weld sequence and display ERR in the upper display and OPT1
8. 12 9 9 PIN PIU IMIOMMANOM eoa te Dus SURE RH ME NU edt n Re Ka ed dcbet 13 5 4 Gun Recommendation Table 13 5 5 Wire Type Size And Feed Speed Capability Table 13 5 6 Installing And Threading Welding 41 14 5 7 Setting Internal DIP SWIIChes x ous ex s eoe cae OD SO C ae ae Lis 15 5 8 Power Source Selection Mende x cn ex a ex mc ee x de Ee vaca dd 16 SECTION G OPERATION 17 6 1 Operational De ERG mel Ve an Ren ccd E 17 6 2 Power SWICK uss aos La ad AA a cos aoa dn hau KEV ae cu fuh 17 ps3 Program Push BUDE en and Ce Sn ea att 17 6 4 Front Panel onirols c osa d dard eu ar d 18 0 5 Upper Display dace des MR 19 6 0 Owen DISDIAV dn ose rtc hue rl dia o 20 6 7 Setup Push gt eae 20 6205 AIS D COMPOSE ieee aa ear eget ROS 21 6 9 Sequence PUSMBUION eras qune V a quin 21 E REAL NER RE CNE A 22 Os JO PU
9. 9 M1 201 231 Motor Gear 1 8Hp 24VDC High Speed Optional 1 sia 9 SUME site 209 131 Motor Gear 1 8Hp 24VDC Low Speed Optional 1 153491 Kit Brush Replacement Consisting Of 1 RE TT te fe pas 159492 sanes GAD BUSI le Ne Logs ie 2 ea E ney EAS 153 493 BUSCADO ane a BAC a ENG tes 2 184 136 Kit Brush Holder 1 aec see co 155 098 Kit Cover Motor Gearbox Consisting Of 1 153 550 Cover Motor Gearbox Consisting Of 1 SOC 155 099 Gasket Cover 1 155100 x21 MED 19408 1 2 e e dup ata ae LE 133 493 Ring Rtng Ext 250 Shaft Grv X 025Thk 1 AE 203 631 Pressure Arm S L Vert S R 4 Roll Consisting Of 1 Tun 203641 Washer Flat Indicator Spring Tension 2 NIMM 182415 Pin Cotter Hall 2 21 n dtc ity rre Foe grt tice C mines 1 203 640 Knob W Extension
10. in the lower dis play OM 1500 9 Page 23 6 10 Auxiliary Menus Continued OPT2 e f the Setup push button is pressed the unit allows OPT2 to be disabled or enabled The upper display shows OPT2 Lower dis play shows or Off The Adjust Control is used to select either On or Off OPT2 is a second input that may be used with an external device such as a gas flow switch to end the weld sequence The gas flow switch may be used to stop the weld se quence if shielding gas flow to the gun is inter rupted A closed set of contacts between pins 1 and 2 of RC24 on Interface Board PC20 will allow feeder to operate normally Opening the contacts will stop the weld sequence and display ERR in the upper display and 2 in the lower display Display Hold Display hold indicated by DISP in the upper display is set to OFF or HOLD in the lower display When HOLD is selected the unit will 6 11 Jog Purge Pressing the Jog Purge switch allows the op erator to jog wire without energizing the weld power or gas valve circuit e The unit provides the ability to jog the wire feeder by means of the gun trigger or the Jog Purge switch If the welding arc does not initiate in 3 seconds after the gun trigger is activated the unit will perform a jog opera tion for a maximum of two minutes If the gun OM 1500 9 Page 24 hold the last weld information for 5 seconds following w
11. lease trigger to clear error OM 1500 9 Page 19 6 6 Lower Display T quu 1 Models Wire Speed e gt 1 Lower Display The lower display shows wire speed or amperage The unit displays and adjusts only preset wire speed at idle When the unit is in a welding state actual wire speed is displayed for the active welding sequence 2 Lower Display Push Button Press button to choose between wire speed or amperage functions 3 Lower Display Push Button LED The lower display push button LED illuminates 6 7 Setup Push Button 3 4 Te Trigger Hold Dual Schedule 1 Exc Setup Non CE Models 1 Setup Push Button Press button to choose between trigger hold or dual schedule functions 2 Setup Push Button LED 3 Trigger Hold LED 4 Dual Schedule LED e When the Setup button is pressed the Set up push button LED flashes and the Trigger Hold LED flashes e The flashing LED indicates that the unit is in the trigger hold display mode In this mode the upper display indicates HOLD and the lower display indicates the trigger hold sta tus On Off Use the Adjust control to change OM 1500 9 Page 20 to indicate that information displayed can be changed by the Adjust control 4 Wire Speed LED 5 Amps LED The LEDs below the display illuminate to indi cate which value is being shown e If the unit is in a welding state that does not involve feeding wire the unit displays
12. Burnback B Start Time Preflow Qu Postflow Time Time Im AM Time Burnback Preflow Run In Start Weld Crater Postflow Trigger Trigger Pressed Released OM 1500 9 Page 25 SECTION 8 SETTING DUAL SCHEDULE PARAMETERS 8 1 Optional Dual Schedule Switch Diagrams Maint 2P Maintained Contact 2 Pole Switch Maint 1P Maintained Contact 1 Pole Switch SECTION 9 MAINTENANCE 9 1 E T Maintenance Clean and ONN OF Replace tighten replace 2 VN unreadable weld cracked Ra labels terminals weld cable Replace Check gas cracked CET 14 pin cord hose and y Check gun parts e fittings cable 6 Months Blow out or vacuum inside During heavy service clean monthly 0 drive rolls Clean 7 OM 1500 9 Page 26 9 2 Diagnostics Y 77777 NY KA would be in place The following error messages are shown on the upper and lower displays to indicate specific errors Explanations are in the text below Wrapper Motor Control Board PC1 LED3 DIP Switch S1 N 7 There is a two position DIP switch 51 located on motor control board PC1 These switches are factory set in the off position and must remain in that position for the unit to op erate correctly Front panel is shown removed for pur
13. cade beatin ake Les dod ac oda ce nat e e Doe e I dee Oe d 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 12 Signification des SyImbDOIlBS s porc eat UON ert dae us Rene ded 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 2 4 Principales normes de S curit x date whee eon S actas AI ae 8 2 5 Information sur les champs lectromagn tiques 8 SECTIONS DEFINITIONS 5 x see doa aue mienne v EC Ero race nous 9 3 1 Warning Label sete talkie Cem a o Ree ui teta Rar ele a ORE v Ss oet 9 3 2 Rating Label For GE Ot De RR t D eb e vea de tate dis 10 3 3 Symbols And DEMONS fis suci sear cte Ce SORORE oe dou La dures 10 SECTION 4 INTRODUCTION eee RIS iex NS 11 4 1 SpeclliGallOfiS x xxr UH X cp rab XR eR ce oe doo om d oo eal ee 11 SECTION 5 1 cient xor eie ewe te sb PES 11 5 1 Ste SelecHOn us SV cris Rhee DR CURE RETE vete haw ewes wee 11 5 2 Rear Panel Connections And Rotating Drive
14. dELT on the Upper Display and 452 on the Lower Display meaning that a Del taweld 452 is the default power source and has a voltage range of 10V as Vmin and 38V as Vmax At power up the operator has three seconds to select a default power source from the list shown on the display Operator scroll through the list of power sources by using the Adjust control After se lecting a power source the operator has three seconds to change to a different power source or begin welding After making a power source selection the operator may press the Program Button to avoid having to wait the three seconds When turning off the feeder the de fault power source will be retained If voltage settings have already been set with the Vmin and Vmax in the Auxiliary Menu selecting a de fault power source with the Power Source Selection Menu overrides the Vmin and Vmax voltage set tings Next Time Feeder Is Turned On The feeder will display the last se lected default power source The operator has three seconds to se lect another power source or press the Program Button to exit the Pow er Source Selection Menu Disabling The Power Source Selection Menu Once the default power source has been selected the Power Source Selection Menu may be disabled using the Auxiliary Menus See Section 6 10 SECTION 6 OPERATION 6 1 Operational Terms The following is a list of terms and their definitions as they appl
15. NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 5 90 Days Parts Guns TIG Torches Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 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 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 MILLER PRODUCTS ARE IN
16. causera des champs lectromagn tiques II y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lec triques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes OM 1500 9 Page 8 Boulevard Rexdale Ontario Canada M9W 183 800 463 6727 ou Toronto 416 747 4044 site www csa international org telephone Internet Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 de American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March P
17. e acit re eate dest Mae 1 135 205 Nut Stl Slflkg Hex Reg 625 11 W Nylon Insert 1 ER 200 556 SUDPOM SDOOL i periret Det i ede sav Ree a ear eee oe 1 IL MR 201 781 Knob W Extension Clamp 1 5 d ed rein acier 156243 Clamp Motor TOD iere aceto ette oe ce S t eor eet 1 Alle Dre de co 145 639 Strip Buna N Compressed Sheet 062 X 4 000 X 4 000 1 Sata 200 552 uim 1 Eu cR 134 306 Foot Rubber 1 250 Dia X 1 375 High No 10 Screw 4 wo 200 557 lt Stiffener c uet oai ase oe dh d wm idee 1 Tu CE Figure 11 2 Control BOX 1 When ordering a component originally displaying a precautionary label the label should also be ordered 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 1500 9 Page 31 5 Hardware is common not available unless listed 8 r9 10 11 11 10 12 13 24 14 802 802 Figure 11 2 Control Box Item Diagram Part No marking No Description Quantity Figure 11 2 Control Box Figure 11 1 Item 21 RU AE 200 555 Wrapper
18. flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection T WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric s
19. guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine Miller Hobart replacement parts H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e Toreduce possible interference keep weld cables as short as possible close together and down low such
20. or time The unit displays both preset and actual arc voltage When the unit is in a welding state actual arc voltage is displayed The upper display shows welding sequence time when the Time LED is illuminated 2 Upper Display Push Button Press and hold button to adjust or display weld time Release button to display voltage 3 Upper Display Push Button LED The upper display push button LED illumi Non CE Models _ T Time ee nates to indicate that information displayed can be changed by the Adjust control 4 Volts LED 5 Time LED The LEDs below the display illuminate to in dicate which value is being shown At any time while welding the unit permits the adjustment of the weld sequence voltage and overrides the display of actual arc volt age e If the unit is displaying a welding sequence that can be timed the welding time display mode is entered by pressing the upper dis CE Models 3 play push button repeatedly until welding time is the active parameter in the upper display At idle the upper display toggles between showing weld voltage or weld time with subsequent presses of the up per display push button The unit defaults to displaying welding voltage when a welding sequence display mode is first entered If the weld sequence has a time set as in spot time after the weld program is com pleted ERR TRG 1 will be displayed to in dicate the weld program is complete Re
21. sous vo tre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistantes et ignifuges cuir coton lourd ou laine et des bottes de protection LE SOUDAGE peut provoquer un RIZ incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peuvent provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion une surchauffe ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soi gneusement avec des protections homologu es e Ne pas souder dans un endroit des tincelles peuvent tomber sur des substances inflammables e Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud e Des tincelles et des mat riaux chauds du soud
22. 00 9 Page 35 S O4 SZL X ze g 219 v09 M Sro pue epinD ue surejuoo yy WW 25 LoS 6v 8 c LoS 67 E WW 7 s 6v WLW QO 6v 8 6v 9 820 ISI 6 lt me 2660 5 198 c HZ 90 970 19 296 251 090 ISI 202 640 vO ISI LEZ 640 920 ISI 296 25 690 ISI 902 90 191 604 640 VLO 19 L96 251 890 ISI 202 90 LvO 19 012 640 20 ISI 096 c 290 19 702 640 LSL Ul 220 890 696 251 990 191 802 650 20 ISI 996 251 990 ISI 902 640 660 ISI 669 290 620 LSL 06 280 40 19 996 c 687 280 040 19 296 cel 590 ISI LOZ 640 250 191 269 640 200 191 616 em 819 67 E 819 E 6 0 819 6 1 m 80 819 E ww 9 0 OUJON uonoeJJ O61 LOL 856 251 290 ISI 000 220 960 191 004 640 920 LSL 969 640 920 191 021 280 cO ISI Ul 20 ECO N 8 VSO 19 cOZ 650 860 191 869 650 HOH NOU p 108 SANG 11004 9 9N 3J3AOOuH9 MA 8 0089 1AOO49 A SHY SIM PUV IANA 1 11 91921 3 D 1500 9 36 Notes Work like a Pro Pros weld and cut safely Read the safety rul
23. EC 92 31 EEC 133 04 93 68 EEC Standards Arc Welding Equipment Part 5 Wire Feeders IEC 60974 5 Ed 1 Arc Welding Equipment Part 10 Electromagnetic Compatibility EMC Requirements IEC 60974 10 August 2002 Arc Welding Equipment Part 1 Welding Power Sources IEC 60974 1 Ed 2 1 Degrees Of Protection Provided By Enclosure IP Code IEC 60529 Ed 2 1 Insulation Coordination For Equipment Within Low Voltage Systems Part 1 Principles Requirements and Tests IEC 60664 1 Ed 1 1 The product technical file is maintained by the responsible Business Unit s located at the manufacturing facility dec wire 6 05 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 3 05 Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage 4 Marks a special safety message Means Warning Watch There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols Means Note not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified pers
24. ES VOLANTES peuvent blesser les yeux pw re e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 1500 9 Page 6 LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche e Ne pas toucher aux pi ces chaudes utiliser les outils recom mand s et porter des gants de soudage et des v tements pais pour viter les br lures LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque rester distance e Les porteurs d un stimulateur cardiaque doi vent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l o
25. For soft wire or small diameter stainless gt To adjust drive roll pressure hold nozzle liner for the welding wire size When steel wire reduce drive roll pressure on about 2 in B1 mm from nonconductive installing position liner the rear roll to half that of the front rolls surface and press gun trigger to feed wire extending from outlet wire guide as against surface Tighten knob so wire close as possible to drive rolls without does not slip Do not overtighten If con touching tact tip is completely blocked wire should slip at the feeder see pressure adjust Install gun Lay gun cable out straight Cut off ment above Cut wire off Close cover end of wire Push wire through guides up to drive rolls continue to hold wire Press Jog button to feed wire out gun Ref 156 929 A Ref 150 922 Ref 156 930 802 954 5 0627 OM 1500 9 Page 14 5 7 Setting Internal Switches NE 1 DIP Switch S1 D DU 2 Switch 54 Not For Customer Use DIP switch 51 allows the user to make a num ber of choices affecting unit operation Defining Motor Speed 51 7 8 Switches 7 and 8 allow the user to define whether the motor in use is standard speed 50 780 inches per minute or high speed 92 1435 inches per minute or low speed 19 300 inches per minute 5 When DIP switch positions are changed the unit must be turned Off and then On again in order for the new settings to be active DIP switches
26. OFF run in is disabled Burnback e f the Setup push button is pressed the unit allows burnback time to be set Burnback time and voltage can be specified when the lower display indicates BURN and the upper display indicates the burnback time or voltage The Adjust control is used to set the desired burnback time or voltage Burnback settings like run in settings are program spe cific The active program is displayed in the Program display and can be adjusted see Section 6 3 Trigger Hold Setup e f the Setup push button is pressed the unit allows trigger hold delay time to be set Trigger hold delay time is indicated by HOLD in the lower display and the hold delay time in the upper display The adjust control can be used to specify a new delay time for trigger hold Trigger hold delay time is the minimum amount of time the trigger must be held for trig ger hold to work when the trigger is released the trigger hold function must be on For ex ample if a trigger hold delay time of 2 0 sec onds is defined the operator must hold the trigger for at least 2 seconds before releasing it in order for the trigger hold function to work Once the trigger hold function is in effect the wire feeder will stay On until the trigger is pressed and released again e There is an additional function built in called maximum trigger hold time which is the maximum length of time the trigger can be held and the trigger hold functi
27. ON 10 lt lt RC27 10 tuc RC3 2 RC7 2 gt 277 I x 27 Zu PS COMMAND PS COMMAND OM 1500 9 Page 28 Notes OM 1500 9 Page 29 SECTION 11 PARTS LIST Hardware is common and not available unless listed 802 712 Figure 11 1 Main Assembly OM 1500 9 Page 30 Item Part Description Quantity Figure 11 1 Main Assembly bake le rar bon tek an 159 647 Insulator Motor 1 TT vL 159646 Clamp Motor 1 Ne ES 159 360 Insulator Screw Machine 4 RS Figure 11 3 Drive Assembly 1 TU PT PII 141 753 Hub Spindle Assembly Consisting Of 1 TE X NT 058 427 Ring Retaining 5 1 Pa Ce 180 571 Shaft Support Spool 1 TL 010233 Spring Cprsn 970 Od X 120 Wire X 1 250pld 1 eae eee 057 971 Washer Flat Stl Keyed 1 500dia X 125thk 1 NO cou 010 191 Washer Fbr 656 Id X 1 500 Od X 125thk 2 Eu WE Rd 058 628 Washer Brake Stl exi ERE RE E Rie E adds 2 icut inen ET RIT 058428 i UD SOON A el cest ta
28. R Sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et les circuits internes de la machine e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal sont galement sous tension lorsque l alimentation est sur Marche avec la pi ce souder ou la table de travail le plus pr s possible de la Dans le mode de soudage avec du fil le fil le d rouleur le bloc de soudure commande du rouleau et toutes les parties m talliques en contact e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec le fil sont sous tension lectrique Un quipement install ou mis avec tout objet m tallique a la terre de mani re incorrecte ou impropre constitue un danger Ne pas raccorder plus d une lectrode ou plus d un c ble de masse Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol une m me borne de sortie de soudage reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indi qu es dans la partie Entr
29. Short Pressure 1 RAR 182 150 MING des QE A Dh A te nti eot eate 2 OM 1500 9 Page 34 Diagram Part No marking No Description Quantity Figure 11 3 Drive Assembly Wire Figure 11 1 Item 4 continued 192 1595 2 132 746 324 BUSHING SPINO 2 be c1 203 633 2 CNA 1 203 632 Carrier Shaft Dual Knob 1 TEIL 133 739 Washer Flat Buna 375 Id X 625 Od X 062Thk 2 203 637 Knob W Extension Long Pressure Arm 1 xs cas POST quss 201 225 Circuit Card Digital Tach Consisting Of 1 TORRENT PEGS 2s 191 204 lt gt Connector SockKelS LEE Ub SD Cote e ae 1 604 311 Grommet Rbr 250 Id X 375mtg Hole 062 Groove 1 Eom 1920611 2 Optical Encoder DiSC don e debe toe dre mem tete 1 iie um ques red en E 603 115 Weather Stripping Adh 125 X 375 1 Pc EE 167387 vs Spacer LOCAUAG alone oda eg 2 TIT ETE 1686825 DIV PIRION Geen dau cr 1 133 308 Ring Retaining Ext 375 Shaft X 025thk
30. TENDED 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 Millers option of repair or replacement will be 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 AN
31. Y 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 2006 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City otate Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Heplacement Parts Training Schools Videos Books Technical Manuals Servicing Informa
32. age peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Afin d liminer tout risque de feu tre vigilant et garder toujours un extincteur la port e de main e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le cable de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites gel es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans revers des bottes et un casque e Avant de souder retirer toute substance combustible de ses poches telles qu un allumeur au butane ou des allumettes e Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur proximit DES PARTICUL
33. are only read on power up 1 gt In the DIP switch S1 illustrations the elevated slider on each switch is shown in white For example the switches above are all in the Off position 802 808 Position Settings And Results For DIP Switch S1 es per minute or 1 2 19 8 minute or 0 4 7 6 meters per meters per minute minute 7 Off 8 On High speed motor 92 1435 inches per minute or 2 3 36 4 meters per minute 7 Off 8 Off Standard 7 On 8 On Low Speed speed motor 50 780 inch Motor 19 300 inches per OM 1500 9 Page 15 5 8 Power Source Selection Menu Non CE Model Shown gt Program Volts Time 4 Wire Speed Amps Start 2 Crater Trigger Hold Pre Postflow Dual Schedule L Sequence Power Source Upper Display Lower Display Voltage Range E For power sources not listed pick a matching voltage range or see Sec 5 10 to set Vmin and Vmax OM 1500 9 Page 16 1 Upper Display 2 Lower Display gt When the feeder is turned the Power Source Selection Menu allows the operator to se lect a default power source Selecting a default power source automatically sets the correct Vmin and Vmax set tings for adjusting the output voltage of the power source First Time Feeder Is Turned On The feeder automatically goes into the Power Source Selection Menu The feeder displays
34. ark Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Maintenir les cables ensemble en les tordant ou en les enveloppant 2 Disposer les cables d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les cables autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la sou dure En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder ou d approcher des op rations de soudage Si le m de cin approuve il est recommand de suivre les proc dures pr c dentes SECTION DEFINITIONS 3 1 Warning Label Definitions Warning Watch There are possible hazards as shown by the symbols A B C 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 Wear dry insu
35. as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e lfinterference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause A Engine exhaust contains chemicals known to the State of birth defects and in some cases cancer California Health amp California to cause cancer birth defects or other reproductive Safety Code Section 25249 5 et seq harm For Gasoline Engines For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling OM 1500 9 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding So
36. ating Current X Duty Cycle D E H Z Hertz gt olo Wire Feed ojo Jog Output Ge Trigger i Line Connection gt Set Sequence EL Trigger Hold On o Trigger Hold Off 7 din Press To Set Start Crater t Time t 5 Preflow Time 5 2 Postflow Time Read Instructions A Y b Increase 1 Primary Current 2 Rated Current 2 Load Voltage 1 gt Dual Schedule OM 1500 9 Page 10 SECTION 4 INTRODUCTION 4 1 Specifications Type of Welding Power Wire Diameter Welding IP Overall Input Power Source Type Wire Feed Speed Range Range Circuit Rating Rating Dimensions Welght 24 Volts AC Constant Voltage Standard 50 To 780 ipm 023 To 1 8 in 100 Volts IP 21 Length 27 in 45 16 Single Phase CV 1 2 To 19 8 mpm 0 6 To 3 2 mm 750 686 mm 20 4 kg 10 Amperes DC With 14 Pin 10096 Duty Width 12 1 2 in 50 60 Hertz And Contactor Optional High Speed 92 To Max Spool Cycle 318 mm Control 1435 ipm 2 3 To 36 4 mpm Weight 60 Ib 27 kg Height 14 in Optional Low Speed 19 to 356 mm 300 ipm 0 4 to 7 6 mpm SECTION 5 INSTALLATION 5 1 Site Selection Do not put feeder where welding wire hits cylinder Do not move or operate equipment when it could tip 1 Wire Feeder Rubber Feet Choose slot that allows all rubber feet to sit securely on top of welding power source 3 Wi
37. ations de s curit des mat riaux MSDS et tension constante fil 2 un poste souder DC manuel lectrode les instructions du fabricant concernant les m taux les consommables les ou 3 un poste souder AC tension vide r duite Dans la plupart des rev tements les nettoyants et les d graisseurs situations l utilisation d un poste souder DC fil tension constante e Travailler dans un espace ferm seulement s il est bien ventil ou en est recommand e En outre ne pas travailler seul portant un respirateur alimentation d air Demander toujours un sur Couper l alimentation ou arr ter le moteur avant de proc der veillant d ment form de se tenir proximit Des fum es et des gaz de l installation la r paration ou l entretien de l appareil D verrouiller soudage peuvent d placer l air et abaisser le niveau d oxygene provo l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de quant des blessures ou des accidents mortels S assurer que l air de s curit respiration ne pr sente aucun danger e Installer le poste correctement et le mettre la terre convenablement Ne pas souder dans des endroits situes proximit d op rations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de pulv risation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs et former des gaz h
38. ator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 1500 9 Page 1 RAYS burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from
39. aute zl ment toxiques et irritants e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer e Ne pas souder des m taux munis d un rev tement tels que l acier gal que le fil de terre du cordon d alimentation est bien raccord la borne vanis plaqu en plomb ou au cadmium moins que le rev tement n ait de terre du sectionneur ou que la fiche du cordon est raccord e une t enlev dans la zone de soudure que l endroit soit bien ventil et en prise correctement mise la terre portant un respirateur alimentation d air Les rev tements et tous les En effectuant les raccordements d entr e fixer d abord le conducteur m taux renfermant ces l ments peuvent d gager des fum es toxi de mise la terre appropri et contre v rifier les connexions ques en cas de soudage OM 1500 9 Page 5 LES RAYONS D ARC peuvent entrai ner des br lures aux yeux et la peau Le rayonnement de l arc du proc d de soudage des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provo quer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage approuv muni de verres filtrants ap propri pour prot ger visage et yeux pendant le soudage voir ANSI 249 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me
40. ciety Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding 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 of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To
41. de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistati ques pour stocker d placer ou exp dier des cartes PC DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en enga geantle fil de soudage gt 2 4 Proposition californienne 65 Avertissements Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants procr ation Se laver les mains apr s manipulation Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l tat de Californie reconnait qu ils provoquent des can cers et des mal
42. e dual schedule status if desired Pressing the Setup button again exits the Setup mode The dual schedule LED stops flashing to indicate the dual schedule status is Off While in the Setup mode the active program can be adjusted without deactivating the trigger hold Setup mode operation If the trigger is activated Setup mode s is termi nated 6 8 Adjust Control Le Adjust Non CE Models 6 9 Sequence Push Button Start Crater Pre Postflow Sequence Non CE Models 5 For more information on Setting Sequence Parameters see Section 7 1 e The Sequence push button allows the selection of welding sequences Five weld ing sequences are available The default sequence is the Weld sequence The Weld sequence is active on power up Three welding sequence LEDs are located above the Sequence push button Start Crater and Preflow Postflow The applicable LED illuminates to indicate which welding se quence is active The LED illuminates to indicate that a weld ing sequence display mode other than Weld is activate Welding sequences other than Weld must be set prior to initiating the arc When the unit enters a welding state all se quence display modes are terminated and TO CE Models CE Models the weld display mode is activated If zero time is programmed for a timed se quence except for Weld that sequence will be skipped In the weld sequence display mode the Se quence push bu
43. eld termination If any front panel push button is pressed or if the Adjust control is activated the display hold feature is termi nated Software Revision Level e f the Setup push button is pressed the unit displays the software version being used by the interface PCB PC20 e Whenthe Setup button is pressed again the menu repeats Code Upon leaving the auxiliary menu the user is asked if a password code indicated by in the top display should be activated By default the code is off indicated by OFF in the lower display The user may enter a nu merical password between 0 and 999 by turn ing the Adjust control When the user re en ters the auxiliary menu the password code trigger is still activated after two minutes the jog operation is terminated to prevent com plete despooling of the wire in the case of a damaged gun e The unit displays the ERR TRIG message to inform the operator that the trigger is acti vated e Jog speed can be adjusted by the Adjust control when the unit is jogging wire The must be selected to gain access to the auxilia ry menu A failed attempt return the user to the weld screen and a counter is incremented A counter in the program display shows the number of incorrect attempts The user has five attempts to enter the correct password code before being locked out of the auxiliary menu indicated by LOCK in the lower dis play The power may be cycled to contin
44. elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suf fisamment de personnes pour soulever et d placer les bouteil les e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curi t 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SUR CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal e R duire le courant ou le facteur
45. er past the postflow phase in a timed weld This error also occurs if the trigger is held when the feeder is powered up The er ror may be cleared by releasing the trigger ERR TCH1 e The tach error occurs 2 seconds after the loss of tachometer feedback The user may continue to weld with this error The motor No gas flow detected Optional error condition speed is regulated through the monitoring of voltage and current ERR MTR1 e The motor error indicates that the motor has been drawing too much current for too long To remedy this reduce the wire feed speed or the wire feeder torque load duty cycle ERR OPT1 e The optional 1 error indicates no coolant flow in water flow switch option The error may be reset by reestablishing coolant flow to the gun and then pressing any button on front panel ERR OPT2 e The optional 2 error indicates a problem with optional device connected to RC24 on Interface Board PC20 The error may be reset by correcting the problem and then pressing any button on front panel OM 1500 9 Page 27 200 592 gu 9 go EE D LL EC T 86 565 DETACHMENT OPTION OR 959925665 WHEN USED AS SWINGARC D 2 B TRICGER 5 6855 2 RECEPTACLE olx m ng E 2 pole Eur 8 28899 2 2080 pec Iu lt RC6 4 9 55 o o EN 7 5 TELEK 4
46. es at the beginning of this manual Warranty Questions Call 1 800 4 A MILLER for your local 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 step of the way Miller Effective January 1 2006 Equipment with serial number preface of LG newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied 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 instructio
47. es gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie comme provoquant des cancers et des malformations cong nitales ou au tres probl mes de procr ation OM 1500 9 Page 7 2 5 Safety Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Principales normes de s curit Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases Cylinders CGA Pamphlet P 1 de Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 2 6 Information Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de souda ge
48. etien avant de toucher les pi ces Ne pas se servir de source lectrique courant lectrique dans les zo nes humides dans les endroits confin s ou l on risque de tomber LES FUM ES ET LES GAZ peuvent e Se servir d une source lectrique courant lectrique UNIQUEMENT si etre dangereux le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n Le soudage des fum es et des gaz Leur cessaire se servir de la fonction de t l commande si l appareil en est inhalation peut tre dangereuse pour la sant quip e D autres consignes de s curit sont n cessaires dans les conditions Ne pas mettre sa t te au dessus des vapeurs Ne pas respirer ces va suivantes risques lectriques dans un environnement humide ou si l on peurs porte des v tements mouill s sur des structures m talliques telles que e Alint rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de sols grilles ou chafaudages en position coinc e comme assise ge l arc pour l vacuation des fum es et des gaz de soudage noux ou couch e ou s il y a un risque lev de contact in vitable ou e Sila ventilation est m diocre porter un respirateur anti vapeurs approu accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC e Lire et comprendre les sp cific
49. formations cong nitales ou autres probl mes de DES ORGANES MOBILES peuvent provoquer des blessures e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire le manuel d utilisation avant d utiliser ou d intervenir sur l appareil e Utiliser uniquement des pi ces de rechange Miller Hobart LE RAYONNEMENT HAUTE FREQUENCE HF risque de provoquer des interf rences e rayonnement haute fr quence HF peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appareil Effectuer r guli rement le contr le et l entretien de l installation Mainte
50. hock sparks and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements OSHA 1910 252 2 and NFPA 51B for hot work and have a fire watcher and extinguisher nearby ou E FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 1500 9 Page 2 4 BUILDUP GAS injure kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns Do not touch hot parts bare handed e Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equ
51. ing VMIN and VMAX will override the default power source set tings 5 The power source selection menu must be set to OFF when overriding the de fault VMIN or VMAX settings Power Source Selection Menu e f the Setup push button is pressed the unit allows the Power Source Selection menu to be disabled or enabled The upper display shows PSS Lower dis play shows or Off The Adjust Control is used to select either On or Off Arc Time e f the Setup push button is pressed the unit displays arc time in hours Arc time is indicated by the Program display showing HR Arc time is shown in the lower display Cycles e f the Setup push button is pressed the unit displays the number of cycles Arc cycles are indicated by the Program dis play showing CL The arc cycle count is shown in the lower display Run In e f the Setup button is pressed the unit allows setting the run in modes The run in modes are program specific Each program may be set to its own run in mode The upper display indicates RUNI The lower display indicates AUTO meaning the factory set automatic run in speed is se lected Pressing the lower display button allows a manual setting the run in wire speed Speed may be adjusted from 1096 to 100 of weld wire speed Pressing the lower display button allows dis abling of the run in feature When the lower display indicates
52. intenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in 252 exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model 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 specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Miller Mil_Thank 4 05 TABLE 5 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 Symbol Usage ws sev saurai wth toads dus KA wit wie Roo opes see aw pce t eels 1 1525 AC Welding Hazards dpi 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 06 3 1 Principal Satety Standards oe a sive ne rci dr MR ee chen Ce hl cR VAR P UR a n da RN 4 156 EME Informallon 22
53. ipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when oylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Mai
54. is mati re de s curit indiqu es ci dessous ne constituent qu un Ne pas utiliser des c bles us s endommag s de grosseur insuffisante sommaire des instructions de s curit plus compl tes fournies ou mal piss s de dans la Section 2 5 Lireet Ne pas enrouler les c bles autour du corps id pa Sila pi ce soud e doit tre mise la terre le faire directement avec un Seul un personnel qualifi est autoris installer faire fonction c ble distinct ner entretenir et r parer cet appareil e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre Pendantle fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine sonnes notamment les enfants de l appareil Ne pas toucher des porte lectrodes connect s deux machines en 3 m me temps cause de la pr sence d une tension vide doubl e E UNE DECHARGE ELECTRIQUE peut e N utiiser qu un mat riel en bon tat R parer ou remplacer sur le 9 entrainer la mort champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Le contact d organes lectriques sous tension peut e Porter un harnais de s curit si doit travailler au dessus du sol e S assurer que tous les panneaux et couvercles sont correctement en graves Le circuit de l lectrode et de la pi ce est TPR aedes
55. it the reset menu Auxiliary Menu e An auxiliary menu is provided if both the Se quence and Setup push buttons are pressed simultaneously The Setup push button and sequence push button LEDS flash when the auxiliary menu is displayed Pushing the Setup push button will step through the menu Pushing the sequence push button will step through the menu in re verse gt The auxiliary menu may be exited at any time by pressing both the Sequence push button and the Setup push buttons simul taneously V Min And V Max e f the Setup push button is pressed the unit allows the setting of the manual override power source min and max voltage preset range The minimum voltage is displayed in the upper display and the lower display indi cates VMIN When the Setup push button is pressed the unit displays the maximum voltage setting of the welding power source The maximum voltage is displayed in the up per display and the lower display indicates VMAX In both cases the Adjust control is used to specify the minimum and maximum voltage settings of the welding power source The set tings correspond to arc voltage obtained at minimum command and arc voltage obtained at maximum command This method of setting VMIN and VMAX may be used if the power source being used is not listed in the Power Source Selection Menu gt If a default power source has already been selected with the Power Source Selection menu sett
56. lating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Don t weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watch person ready to use it 3 3 Do not weld on drums or any closed containers 4 Arcrays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body S 178 936 protection 5 Become trained and read the instructions before working on the machine or welding 6 Donotremove or paint over cover the label OM 1500 9 Page 9 3 2 Rating Label For Products For label location see Section 5 2 DEP U 24 VN 4 10 0A 1 50 60 Hz IP 21 U gt 100V 12 750 100 3 3 Symbols Definitions Note ea Some symbols are found only on CE products ST 178 794 A A Amperes V Volts EN Altern
57. ng near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION som 3 05 Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes TN zf Ce groupe de symboles signifie Avertissement Attention Risques 2 1 i Symboles utilis s Symbole graphique d avertissement Attention Cette pro c dure comporte des risques possibles Les dangers ven tuels sont repr sent s par les symboles graphiques joints Indique un message de s curit particulier d ELECTROCUTION ORGANES MOBILES PARTIES CHAUDES Consulter les symboles et les instructions aff rentes ci dessous concernant les mesures prendre pour supprimer gt Signifie NOTE n est pas relatif la s curit les dangers 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce manuel V rifier fr quemment le cordon d alimentation afin de s assurer qu il pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort instructions aff rentes pour viter tout risque Les instructions l quipement doit tre hors tension lorsqu il n est pas util
58. nir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique peut g ner le fonctionnement d appareils lectroniques comme des ordinateurs et des robots e Veiler ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail Pour les moteurs essence Les gaz d chappement des moteurs contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres pro bl mes de procr ation Pour les moteurs diesel L
59. ns 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 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls nduction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options
60. ntenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do notinstall unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do SO e Do not point gun toward any part of the body other people or any metal when threading welding wire 3 1 4 California Proposition 65 Warnings STATIC ESD can damage PC boards MOVING PARTS can cause injury e Keep away from moving parts such as fans Keep all doors panels covers and
61. on still work when the trigger is released the trigger hold function must be on The maximum trigger hold time is set at 4 0 seconds after the trig ger hold delay time For example if a trigger hold delay time of 2 0 seconds is defined and the operator held the trigger in for more than 6 0 seconds the trigger hold function would not be in effect and the wire feeder would stop when the trigger is released e When the Setup push button is pressed again the menu repeats to the first menu selection of run in wire speed selection Trigger Program Select e f the Setup push button is pressed the unit allows Trigger Program Select to be dis abled or enabled The upper display shows TSEL Lower dis play shows or Off The Adjust Control is used to select either On or Off Trigger Program Select allows the operator to select programs by clicking the trigger pulling and releasing the trigger in a maximum of 0 2 seconds The feeder will switch between any programs that have a minimum of 0 2 seconds of preflow time set in the weld sequence If pro grams 1 and 3 have a minimum of 0 2 seconds of preflow time clicking the trigger will toggle between programs 1 and 3 If programs 1 2 and 4 have a minimum of 0 2 seconds of pre flow time clicking the trigger will switch from 1 to 2 to 4 to 1 to 2 Any combination of programs may be used Trigger Program Select cannot be used while welding or with Dual Schedule
62. ons should install operate maintain and repair this unit During operation keep everybody especially children away m ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling e Use AC output ONLY if required for the welding process e f AC output is required use remote output control if present on unit e Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental con
63. orkpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place e Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes e ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respir
64. pose of illustration only In actual use front panel Ref 802 687 Indicates a Indicates a trigger communication error error LED3 Related Error Indications Error conditions are indicated by LED3 on PC1 To view LEDS turn Off unit remove wrapper and turn unit On LEDS is most easily observed from the left side of the unit The LED blinks in a 2 5 second cycle The number of blinks in this period indicates the type of error The priority of the errors is related to the num ber of blinks indicating the error The more blinks the more severe the error motor error is top priority A higher priority error overrides a lower one if a motor error and a communica tion error existed the light would blink four times for the motor error Since blink On time and blink Off time are equal in a four blink cycle the four blink se quence appears as a constant blink 1 blink Communication Error 2 blinks Trigger Error 3 blinks Tach Error Indicates a motor error Indicates a tachometer error 4 blinks Motor Error ERR 1 e The communication error occurs 2 5 sec onds after a loss of communication between the motor and front panel boards The user may continue to weld with this error The er ror may be cleared by resetting the unit see Section 6 10 ERR TRG1 e The trigger error occurs if the user has the trigger held for more than two minutes with out striking an arc or if the user holds the trigg
65. re Spool Reel 4 Gas Oylinder w Hose And Regulator Customer Supplied 4 US 1 22 N gt Shielding gas pressure not to exceed 100 PSI 689 kPa 5 Welding Power Source 6 Running Gear Factory voltage settings are V Min 10 and V Max 38 If you are using a power source with a dif ferent voltage range see Sec tion 5 8 for V Min And V Max adjustments Ref ST 152 468 A ST 152 467 C OM 1500 9 Page 11 5 2 Rear Panel Connections And Rotating Drive Assembly 1 14 Control Cable 10 ft 3 0 m 2 Shielding Gas Valve Fitting Requires fitting with 5 8 18 right hand threads Connect customer supplied gas hose gt Shielding gas pressure not to exceed 100 PSI 689 kPa Weld Cable Terminal Weld Cable Drive Assembly Drive Assembly Rotation Knob 7 Rating Label Location To rotate the drive assembly loos en drive assembly rotation knob rotate drive assembly and tighten knob Tools Needed 9 16 5 8in 3 16 802 824 802 825 1500 9 12 5 3 14 Plug Information Pin Pin Information A 24 volts ac with respect to socket G B Contact closure to completes 24 volts ac contactor control circuit G Circuit common for 24 volts ac circuit C 10 volts input from power source to wire feeder with respect to socket D D Remote control circuit common to 10 vol
66. reduce magnetic fields in the workplace use the following procedures OM 1500 9 Page 4 Boulevard Rexdale Ontario Canada M9W 183 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keepcables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body B m m Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor before welding or goi
67. tact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owners Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the w
68. tflow POST When POST is selected the upper display can be used to specify postflow time e When the Sequence push button is pressed a fourth time the unit returns to the welding sequence display mode OM 1500 9 Page 21 6 10 Auxiliary Menus Program Display Program Push Button Sequence Push Button Upper Display Upper Display Push Button Lower Display Lower Display Push Button Adjust Control Setup Push Button Non CE Models 4 mgr gt ON 1 TM BEEN 2 Pro i iE gram Volts Time sec Ki Wire Speed Amps N 6 Start Crater Trigger Hold Pre Postflow Dual Schedule 9 3 Adjust Setup CE Models OM 1500 9 Page 22 6 10 Auxiliary Menus Continued Reset To Factory Settings A reset menu is displayed if the following four push buttons are pressed simultaneously Program Sequence upper display and Set up The upper display indicates WIPE The lower display indicates OFF The lower push button is active indicating that the Adjust con trol can be used to change the unit to WIPE ON When WIPE is set if the original four push buttons are simultaneously pressed a second time the unit will reset all settings to factory default except the arc time and arc cycle counts If a reset is not desired set the display to WIPE OFF and simultaneously press the Program Sequence upper display and Setup push buttons to ex
69. the weld sequence wire speed At any time dur ing welding the weld sequence wire speed can be adjusted and overrides the preset wire speed display In other words if the Ad the trigger hold status or press the lower dis play push button If trigger hold is turned On the trigger hold LED illuminates and stays On When trigger hold is On the user must press and hold the trigger for a predefined amount of time the trigger hold delay time see Section 6 10 then release it for the trig ger hold function to be active To shut off the weld when trigger hold is On the user must press and release the trigger If a weld time is programmed trigger hold is disabled Trigger hold and dual schedule cannot be used concurrently a TT CE Models just control is activated while welding the unit displays and permits adjustment of the weld sequence wire feed speed regardless of the active welding sequence When the unit is displaying amperage the Amps LED illuminates Amperage is only displayed if the unit is in a welding state and the amperage is above a minimum value of 25 Amps The display will read dashes for amperage readings below the amperage threshold prior to arc initiation CE Models e Whenthe Setup button is pressed a second time the dual schedule LED flashes In this mode the upper display indicates DUAL and the lower display indicates dual schedule status On Off Use the Adjust control to change th
70. tion and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA C 2006 Miller Electric Mfg Co 2006 01 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 amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com Miller
71. ts dc output signal from wire feeder to power source with respect to socket D H Voltage feedback 0 to 10 volts dc 1 volt per 10 arc volts F Current feedback 0 to 10 volts dc 1 volt per 100 amperes The remaining pins are not used 5 4 Gun Recommendation Table Process Gun GMAW Hard or Cored Wires Roughneck C Series Guns 300 400 500 And 600 Amp FCAW Self Shielding Wires FC 1260 Or FC 1150 5 5 Wire Type Size And Feed Speed Capability Table Motor Speed Wire Type Wire Size Feed Speed Capability Standard 023 5 64 0 6 2 mm 50 To 780 ipm 1 2 19 8 mpm Standard 3 32 7 64 2 4 2 8 50 To 700 ipm 1 2 17 8 Standard 1 8 3 2 50 To 300 ipm 1 2 To 7 6 mpm All 023 To 5 64 in 0 6 To 2 mm 92 To 1435 ipm 2 3 To 36 4 mpm E All 023 To 1 8 in 0 6 To 3 2 mm 19 To 300 ipm 0 4 To 7 6 mpm OM 1500 9 Page 13 5 6 Installing Threading Welding Wire Install wire spool Adjust tension nut so Install wire guides and wire is taut when wire feed stops anti wear guide Install drive rolls dd Pressure Indicator fo ini LN Tools Needed 3 16 5 64 in E 8 J 15 16 3 8 Drive Rolls Cable End Of Liner C7 Be sure that outlet cable has proper size 5
72. tton LED is Off When the Sequence push button is pressed the Se quence push button flashes and the Start LEDs flash In this condition the unit is in the Start sequence display mode and Start se quence parameters are shown in the dis plays When the Sequence push button is pressed a second time the Crater sequence LED flashes The Sequence push button LED re mains flashing In this condition the unit is in the Crater sequence display mode and Crater sequence parameters are shown in the displays 1 Adjust Control The Adjust control is used to change various sequence parame ters and to select various se quences Hefer to the section for the function in question for informa tion related to using the Adjust con Sequence Push Button Sequence Push Button LED Welding Sequence LEDs Weld Start Time Crater Time Time Preflow Time Postflow N NS Time Welding Sequence Diagram e When the Sequence push button is pressed a third time the Preflow Postflow sequence LED flashes The Sequence push button LED remains flashing In the Preflow display mode the upper display shows the preflow time and the lower display indicates the ab breviation PRE to inform the operator that preflow time is displayed If the upper dis play push button is pressed the Adjust con trol can be used to adjust preflow If the lower display push button is pressed the Adjust control can be used to select between preflow PRE and pos
73. ue welding but the user will remained locked out of the auxiliary menu Pressing the Program Sequence upper display and Set up push buttons simultaneously the counter can be re set in the weld screen Resetting the counter is indicated by CODE in the upper display and RSET in the lower display Pressing the Program Sequence upper display and Set up push buttons simultaneously again will al low the user to reset the unit to the factory de faults indicated by WIPE in the upper dis play Resetting the unit will also turn off the password code feature 1 Jog Purge Push Button 2 Adjust Control 3 Gun Trigger Receptacle 802 807 unit displays jog speed when the unit is be ing jogged e Jogging can also be accomplished by pressing the Jog Purge button e Pressing the Jog Purge button also allows the operator to purge gas lines before weld ing and to preset gas pressure at the regulator SECTION 7 SETTING SEQUENCE PARAMETERS 7 1 Sequence Parameters In Program 5 For more information on Sequence Push Button see Section 6 9 If time is set to zero in Weld sequence welding continues until Sequence Parameters gun trigger is released EE Seconds If time is set to zero in any timed sequence except Weld the sequence is skipped m a eer m IN 0 5 00 6 Burnback 0 0 25 T Postflow X Setting available Weld Time Crater Time
74. uie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessi ve des chocs m caniques des dommages physiques du lai tier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support sta tionnaire ou dans un porte bouteilles pour les emp cher de tom ber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifi que les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Lecouvercle du d tendeur doit toujours tre en place sauf lors que la bouteille est utilis e ou qu
75. vice Kit 1 Housing Plug Skts Service Kit 1 Housing Plug Skts Service Kit 1 Label Warning General Precautionary 1 Label Warning General Precautionary Wordless CE 1 Fitting W Screen 1 OM 1500 9 Page 33 5 Hardware is common not available unless listed See Table 11 1 For Drive Roll amp Wire Guide Kits 803 790 A Figure 11 3 Drive Assembly Wire Item Diagram Part No marking No Description Quantity Figure 11 3 Drive Assembly Wire Figure 11 1 Item 4 010 668 Screw Stl Sch 250 20 X 1 500 4 c r 172075 Carrier Drive Roll W Components 4 c 149 962 Spacer Carrier Drive Roll 4 nr PETS 149 486 Pin Rotation Arm Rocker 2 T m TTE 192 790 2 Arm Pressure dedos ara deest te iste ace t M sca ea Ot oe ens em JA 2 CREMA 150 520 Spacer Flat Stl 257 Id X 619 Od X 105 2 rar n 133 493 Ring Retaining Ext 250 Shaft X 025Thk 2 D pd MU de pereo RE JM VIC 1 nig Oo whore 201 230 Motor Gear 1 8Hp 24VDC Standard Speed 1
76. y to this wire feeder General Terms Cold Wire Jog Feeding wire without contactor or gas valve being energized Sequence A portion of the weld program such as preflow run in start weld crater burnback and postflow Weld Program A group of sequences that make up a weld cycle 6 2 Power Switch 1 Power Switch 802 809 A 6 3 Program Push Button 1 Program Display The number of the active program is displayed 2 Program Push Button Press button to activate program select feature To change the pro gram number press the Program push button and rotate the Adjust control 3 Program Push Button LED The LED lights to indicate the Pro gram push button is active Non CE Models CE Models Program AC OM 1500 9 Page 17 6 4 Front Panel Controls Nameplate For Non CE Models See Section 6 5 See Section Program See 6 Section 6 6 Start Crater Pre Postflo e Sequence Section Section Section 6 9 6 8 6 7 Nameplate For CE Models Section See 6 5 Section i See Section See See See Section Section Section 6 9 6 8 6 7 OM 1500 9 Page 18 6 5 Upper Display C7 To set the correct voltage range for a particular power source see Section 5 8 for power source selection menu or Section 6 10 for V Min And V Max adjustments 4 Volts Y 4 7 1 Upper Display The upper display shows voltage

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