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Miller Electric D-74S User's Manual

1. 10 RC72 2 mw 78 zt lt RC72 8 MENS QNI HF STUD 5 lt lt RC95 14 PIN A p PLG12 a a 51 A lt BLACK lt 4 l 22024 lt RC77 2 G lt PURPLE 4 2 c 2 AC COM COM lt RC77 1 B lt 2 CONTACTOR ZL ROJ4 5 c lt FUNK PS 10V lt RO7A 2 Figure 8 1 Circuit Diagram OM 1500 6 Page 24 n S O RT O RR M OC RC11 5 lt lt Re1 3 Fe R PG1 MOTOR BOARD RIGHT THUG HOLD C RCE 2 RC1 PLG1 RC3 PLG3 RC4 PLG4 RC5 PLCS RC6 PLG6 RC7 PLG7 RC8 PLGB RC9 PLG9 RC10 PLG10 RC11 PLG11 lt RC11 2 lt RC11 1 lt RC7 9 lt RC7 10 70 A5 13 14 7222 22 KL RO COM AFOV RC amp 7 10 gt RC67 9 gt RC51 1 gt RCS1 2 gt PC4D OR PC6D MASTER BOARD METER BOARD RO61 PLG21 RO67 PLG67 lt RC11 5 70 l COM RC61 5 gt DIP SWITCH SETTINGS FOR 32 ON METER BOARD PC60 ONLY S2 STD IPM ALL OFF HI SPD IPM STD MPM HI SPD MPM 1 IAN eo z A O i DETACHMENT OPTION OR WHEN USED AS SWINGARC le o E JE REGEPTAGLE es e EC PE E T I Ross gt gt 19 E REN 319392 Su 29900 3 RCE 2 gt p lt 13 PEA 15 gt gt E 2 RC6 1 pie P Bus pE i lz id Q Go S are ORANGE gs EZ RO4 2 gt DY 5 c MME 5 852 651 RC4 1 gt p lt Ms a s 1 xd M WHEN USED AS SWINGARC Mi NE Bu m ae ll RC4 3 gt MD Het E ae lz R E ROB 3 gt gt c se 535 88 Ss 68 B a pose gt p
2. 66 0S wwgo Ut GO ECO 140 LS L 996 C L YSO LS cOZ ESO 860 ISI 615 Gr L 8 0 ISI 869 90 1104 3 01126 N 9AuUq AU a om uon a 93 O JAOOu5D on QJAOOHD MA JAOOWuD JAOOHD A o E 3 S SUM 3PINSH IM PUV JOH SAH L 6 SAB L 2 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 Effective January 1 2005 Equipment with a serial number preface of LF or 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 co
3. 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 Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or n
4. Q Miller OM 1500 6 206 805F May 2005 Processes MIG GMAW Welding Flux Cored FCAW Welding Gas And Self Shielded Description i ES Wire Feeder ce D 745 D 74D O OWNER S MANUAL Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can 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 Y E 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 LUE El jue EE You e f 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 icai eue uus Ios and easy With Miller you can count on years Ni 00012000 of reliable service with proper maintenance And if for some reason the
5. Switch rocker spdt 15A 12V on off on D us uA uae XS d 2422 201 642 Switch rocker spdt 15A 12V on none on 40 Mid Lada S100 201 641 Switch rocker spdt 15A 12V on off on W leds UE A NO 193919 Knob pointer 1 250 dia x 250 id w two set screws 4 4 op RN 206 513 Nameplate Miller D 74S Upper 1 0 DEC UR 206 511 Nameplate Miller D 74D Upper Quiso 7 TL DEMEURE SEE 207 431 Nameplate Upper CE Version D 74S 1 0 yu Dura MR ELE erts 207 433 Nameplate Upper CE Version D 74D asse d 26 RC13 RC113 048 282 RCPT w skts service kit 2 Du de R H ee ee 211 989 30 FIRING W SCKECN a a e haw a ok Bae eee has 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 Dia Part Mkgs No Description Quantity Harness Connectors Receptacles TEREE PLG6 106 115 094 Housing Plug Skts service kit d S PLG4 104 136810 Housing Plug Skts service kit d NO P
6. 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 cote oppose 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 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 tab
7. 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 in OSHA 1910 252 a 2 iv 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 6 Page 2 a BUILDUP OF GAS can injure or 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 equipment can damage hearing e Wear approved ear protection if noise level is high
8. September 1997 Draft Revision Degrees of Protection Provided By Enclosures IP Code IEC 529 November 1989 First Edition Insulation Coordination For Equipment With Low Voltage Systems Part I Principles Requirements and Tests IEC 664 1 October 1992 First Edition Electromagnetic Compatibility EMC EN 50199 August 1995 European Contact Mr Danilo Fedolfi Managing Director ITW WELDING PRODUCTS ITALY S r l Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Telephone 39 02 98290 1 Fax 39 02 98290 203 dec coni 11 02 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _3 05 A Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage i Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols CS Means Note not safety related 1 2 Arc Welding Hazards A 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 persons should install operate maintain and repair this unit
9. Start J Crater T Time ty 5 Preflow Time 5 to Postflow Time Read Instructions b C Increase 1 Primary Current 2 Rated Current U 2 Load Voltage U 1 Primary Voltage gt Dual Schedule OM 1500 6 Page 10 SECTION 4 INTRODUCTION 4 1 Specifications Type of Input Welding Power Wire Feed Speed Wire Diameter iron IP Overall ES Power Source Type Range Range Rating Rating Dimensions g 24 Volts AC Constant Voltage CV Standard 50 To 780 023 To 1 8 in 100 Volts IP 21 Length 35 in 87 Ib Single Phase DC With 14 Pin And ipm 1 3 To 19 8 mpm 0 6 To 3 2 mm 750 889 mm 39 5 kg 10 Amperes Contactor Control Amperes Width 12 1 2 in 50 60 Hertz Optional High Speed Max Spool 100 Duty 318 mm 92 To 1435 ipm 2 3 Weight 60 Ib Cycle To 36 4 mpm 27 kg Height 14 in 356 mm 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 2 Rubber Feet Choose slot that allows all rubber feet to sit securely on top of welding power source 3 Wire Spool Reels 4 Gas Cylinder w Hose And Regulator Customer Supplied E Shielding gas pressure not to exceed 90 PSI 620 kPa 5 Welding Power Source 6 Running Gear Wire feeder shown is representative only and does not reflect actual unit Ref 803 048 OM 1500 6 Page 11 5 2 Equipment Conn
10. 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 6 Page 1 ARC RAYS can 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 an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI 749 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 flash glare and sparks warn others not to watch the arc e Wear prot
11. 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 l arc 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 o 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 soudage 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 t
12. Flowgauge and Flowmeter Regulators No Labor HE Units Grids Maxstar 85 140 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 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 m Miller 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets 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 Equipmentthat 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
13. Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 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 going near welding operations If cleared by your doctor then following the above p
14. arc volts F Current feedback 0 to 10 volts dc 1 volt per 100 amperes The remaining pins are not used 5 5 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 6 Wire Type Size And Feed Speed Capability Table Motor Speed Wire Type Wire Size Feed Speed Capability Standard All 023 To 5 64 in 0 6 To 2 mm 50 To 780 ipm 1 2 To 19 8 mpm Standard All 3 32 To 7 64 in 2 4 To 2 8 mm 50 To 700 ipm 1 2 To 17 8 mpm Standard All 1 8 in 3 2 mm 50 To 300 ipm 1 2 To 7 6 mpm ee All 023 To 5 64 in 0 6 To 2 mm 92 To 1435 ipm 2 3 To 36 4 mpm OM 1500 6 Page 14 5 7 Installing And 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 Pressure Indicator fo ini E N LN Tools Needed diis m 3 16 5 64 in E p I 15 16 3 8 in Drive Rolls yee Of Gun End Of Liner CS For best wire feeding performance be F For soft wire or small diameter stainless gt To adjust drive roll pressure hold nozzle sure that the outlet cable has the proper steel wire reduce drive roll pressure on about 2 in 51 mm from nonconductive size liner for the welding wire size being the rear rol
15. 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 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
16. de la machine e Fixer le cable de retour de facon obtenir un bon contact metal metal 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 e 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 Il 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 Entretien avant de toucher les pi ces e Ne pas se servir de source lectrique courant lectrique dans les zo nes humides dans les endroits co
17. des c bles us s endommag s de grosseur insuffisante sommaire des instructions de s curit plus completes fournies ou mal piss s Glede eles 98 e de dans la Section 2 5 Lireet amp Ne pas enrouler les c bles autour du corps 0 pa l e Sila pi ce soud e doit tre mise la terre le faire directement avec un A Seul un personnel qualifi est autoris a 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 A Pendant le fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine sonnes notamment les enfants de l appareil e Ne pas toucher des porte lectrodes connect s deux machines en x 3 m me temps a cause de la presence d une tension a vide doubl e E UNE DECHARGE ELECTRIQUE peut e N utiiser qu un mat riel en bon tat R parer ou remplacer sur le 0 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 l on doit travailler au dessus du sol Provoquer ca ou 965 Prud rs e S assurer que tous les panneaux et couvercles sont correctement en graves Le circuit de l lectrode et de la pi ce est BED TPR aedes R d sous tension lorsque le courant est d livr la PASG ui sortie Le circuit d alimentation et les circuits internes
18. 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 lfinside 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 respirator Read and understand the Material Safety Data Sheets MSDSs
19. 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 6 Page 9 3 2 Rating Label For CE Products For label location see Section 5 3 DEP Uu 24 VN dus 10 0A 1 50 60 Hz IP 21 Ej Us 100V 1 750 A X 100 3 3 Symbols And Definitions Note ea Some symbols are found only on CE products ST 178 794 A A Amperes V Volts EN Alternating Current X Duty Cycle D E H Z Hertz Program olo Wire Feed ojo Jog gt Output Ga Trigger d gt Line Connection Set Up dV Sequence EL Trigger Hold On o Trigger Hold Off lj Purge din Press To Set
20. 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 e 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 6 Page 5 LES RAYONS D ARC peuvent entrai ner des br lures aux yeux et a la peau Le rayonnement de l arc du proc d de soudage g n re 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 Z49 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 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
21. 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 EGN oA a aaa 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 OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ad OY MPSS AO O ae ae Rae ae ee hae tad li db sd een ade eae 1 152 Are Welding Hazard 2 o oe e kaa Ae de a aa alee Dio aie do qua 1 1 3 Additional Symbols For Installation Operation And Maintenance eens 3 1 4 California Proposition 65 Warnings mrs 3 1958 P ncipal Satety Standards es curn die Peer Dept das Vere gi ridad noz a 4 156 EME TORAH OM asser d oes abled td b oe TTT 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles us pa
22. 1 sso SPACE KOCAUNG vs tus ses SA oak dene Do uus 2 A A 133493 Ring Rtng Ext 250 Shaft Grv X 025thk 1 1 OM 1500 6 Page 30 Quantity Item Dia Part un Model No Mkgs No Description D 74S D 74D Figure 9 3 Drive Assembly Wire Continued PR A E 203 642 Pressure Arm R amp Vert L 4 Roll consisting of 1 1 TT leet ies 203 631 Pressure Arm S L amp Vert S R 4 Roll consisting of 1 1 eee ee eee 203 641 Washer Flat Indicator Spring Tension 2 nsu SED MERO T82 415 ani PIN GOler Mall aestas ao eee uir eat eb d sons 1 EMI 203 640 Knob W Extension Short Pressure Arm E e C saei espe s de 182 156 c SONNO CPIS Meenen a hence e LEUR RE Ee dA DEN ix esit he st eo ns 192 TOS sux OPNO ista rcu i re ENIRO er an o A foa diene a t eu Pauke 2 1G a 132 46 zsz BUSING SHING a4 5 tuts A eed da gaat S wa A eve ening 203 639 2 hall ODINO socia dia A 203 632 Garner Shall iaa da a Sed ia dez A A 133739 Washer Flat Buna 375 Id X 625 Od X 062thk Pid Tuo PEIUS 203 637 Knob W Extension Long Pressure Arm 1 1 21 PC51 151 201225 Circuit Card Digital Tach consisting of 0 2 pes PLOD 55225 131204 Connector amp Sockets Docea 7 TTT 604 311 Grommet Rbr 250 Id X 375mtg Ho
23. A 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 e 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 contact with the workpiece or ground For these conditions use the f
24. ECTION 6 OPERATION 5 KN RRR A K AAA ARA AAA dre 18 b T Power SWICK orar aurae a a ao woe A AAA a cane oe e 18 6 2 Left Right Select SWIC ostra rre a ic A A A Aa 18 G3 JOJ PUNGE nia ii A Dan ao ia a ld doe eis ii En eae wre 18 6 4 Tigger Flold SWICK 23 ii saec io wk P Ce ROC SOR e OS ame dae eed mei ade eee e 19 6 5 Voltage Control And Digital Meters 0 0 eee rn 19 SECTION 7 MAINTENANCE cec0 c00cncoteeseodniees tract eens AH RR RRR eee etes tn eee sade 20 11 Route Malitenance sucre a 20 1 25 DIAQNOSIICS wet cance arranca 21 1 02 A O 22 SECTIONS ELECTRICAL DIAGRAM 25 bm na o RR A A AAA AAA AAA 24 SECTION 9 PARTS LIST lt lt ori AA A AS AAA AA a Sees 26 OPTIONS AND ACCESSORIES WARRANTY Declaration of Conformity for European Community CE Products Note 3 This information is provided for units with CE certification see rating label on unit Manufacturer s Name Miller Electric Mig Co Manufacturer s Address 1635 W Spencer Street Appleton WI 54914 USA Declares that the products D 4 S 5 D 4 D conform to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC Electromagnetic Compatibility EMC Directive 89 336 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Arc Welding Equipment Part I Welding Power Sources IEC 60974 1 September 1998 Second Edition Arc Welding Equipment Wirefeed Systems IEC 974 5
25. ERATION 6 1 Power Switch 1 Power Switch Ref 803 065 1 Left Right Select Switch Pressing the Left Right Select switch allows the operator to choose which side of the unit s con trols will operate Ref 803 048 6 3 Jog Purge 1 Jog Purge Push Buttons 2 Wire Speed Controls 3 Gun Trigger Receptacles Ref 803 048 Pressing the Jog Purge switch allows the op onds after the gun trigger is activated the Speed control when the unit is jogging erator to jog wire without energizing the weld unit will perform a jog operation for a maxi wire If equipped with meters the unit dis power or gas valve circuit mum of two minutes If the gun trigger is still plays jog speed while the unit is being activated after two minutes the jog opera jogged tion is terminated to prevent complete des pooling of the wire as in the case ofa dam e Pressing the Jog Purge button also allows aged gun the operator to purge gas lines before welding and to preset gas pressure at the If the welding arc does not initiate in 3 sec e Jog speed can be adjusted with the Wire regulator e Theunit also provides the ability to jog the wire feeder by means of the gun trigger however the contactor is energized for 3 seconds OM 1500 6 Page 18 6 4 Trigger Hold Switch 1 Trigger Hold Switches Trigger hold allows the operator to weld without holding the gun trigger e To use the trigger hold function place the trigger hold switch
26. LG52 174 823 Housing Plug Pins Skts service kit 1 1 D PLG74 115093 Housing Plug Skts service kit 1 d lisser 605 227 Nut 750 14 Knurled1 68dia 41h Nyl 2 howe 2 13 GS1 GS101 219062 Valve Gas W Fittings 3AVDC D usc uu L nera drame ud d 010 494 Bushing Snap in Nyl 1 375 Id X 1 750 Mtg Hole ida e je A TTT 134 201 Stand off Support Pc Card 312 375w Post amp lock 43 17 17 TERCERO 204 721 4 Enclosure CONTO aes A A AS oe Janus WIES PC60 220 801 Circuit Card Assy Meter W Program 0 1 MA PC40 cea 220 797 Circuit Card Assy Master W Program D 74 1 99 OM 1500 6 Page 28 Quantity ltem Dia Part mn Model No Mkgs No Description D 74S D 74D Figure 9 2 Control Box Continued 18 Aly R101 073 562 Potentiometer cp std slot 1t 2 w 10k linear D 74S 2 s 09 18 H1 101 70 170 224 597 Potentiometer cermet std flat 3 75t 2 w 10k linear D 74D 0 4 c ee EMEN 204 723 Panel Front sauce we e xe ace ende Ce e roce o Ses 1 1 ratto da au qe 204 724 Nameplate Miller Lower 22 tas i xc E 207 428 Nameplate Lower CE Version lasse d fel usi 92 91023 200 295
27. LG72 115092 Housing Plug Skts service kit d ae eee PLG9 109 201 665 Housing Plug Skts Service kit 7 uS PLG11 21 71 111 131 055 Housing Rcpt Skts service kit 1 En PLG7 67 107 115091 Housing Plug Skts service kit 1 AS PLG17 70 158 719 Housing Plug Skts service kit d px R Ex PLG117 165404 Housing Rcpt Skts service kit 1 TENE PLG1 77 78 79 101 202592 Housing Plug Skts service kit oooooooooooooo 1 ceda PLG3 75 76 103 115093 Housing Plug Skts Service kit 1 tods PLG51 174 824 Housing Plug Pins Skts service kit 1 ee PLG8 108 131 054 Housing Rept Skts service kit 1 ri PLG10 110 130 203 Housing Plug Skts service kit 1 OM 1500 6 Page 29 ICS Hardware is common and not available unless listed See Table 9 1 For Drive Roll amp Wire Guide Kits 19 20 803 790 A Figure 9 3 Drive Assembly Wire Quantity Item Dia Par o Model No Mkgs No Description D 74S D 74D Figure 9 3 Drive Assembly Wire Figure 9 1 Item 4 Tm Mu 010 668 Screw Cap Stl Sch 250 20 X 1 500 1 Ae esu Tu e
28. ON e Nr p ROM gt A ee ROZE 60812 2 TS 0 TP TUUS L Rego RC11 2 ESP RE RC71 2 RC78 2 S a 06161 J4 J4 PNK 34 rar gt A RA A 4 lt gt 4 gt lt RC4 1 Rc1 2 gt A II R079 2 o AAA gt WHEN USED AS SWINGARC CONTACTOR E RC76 6 s MABE EEE GLK MITA ELLA SS ES DEA RC3 gt lt RO755 ee Res d E CURAENT FEEDBACK 37 dies j RC76 2 oye A AA cca ee Es RC78 3 UA A 010 no E P Rc3 6 gt VOLTAGE FEEDBACK D ce 075 6 Parr 3 CR MK lt Res NER LS 4100 TE MH RC76 4 gt AAA 20000 2S COM 12 RC3 3 ce M E 2 RC75 3 v RC3 4 gt PS COMMAND LEFT 22 lt lt RC75 4 52 LZ H RC5 3 PC101 t F a 37 RC5 2 RC7 9 o CC J lt lt RC70 1 2l MOTOR BOARD LEFT Wr Sd KG RC5 1 RC1 PLG101 607 10 222 RC70 2 RC3 PLG103 RC4 PLG104 JOG 112 WHEN USED AS Piia m RC 0 5 ur SWINGARC OR WHEN EQUIPPED_W METERS bla Rc10 1 gt 2 VE 102 PC70 RCB PLG108 me A PURGE 703 DUAL CONTROL BOARD a RC70 PLG70 RC9 PLG109 aci id TRIGGER lt RC10 PLG110 dz HOLD EE EE ES S z HF STUD f lt lt 0016 RG10 2 gt RUE ER ou y penu IS HOLD 106 RC77 PLG77 REMOTE VOLTAGE RCB 2 gt RC7B PLG7B OPTION OR WHEN RC79 PLG79 EQUIPPED W METERS TRIGGER RC95 LEAD95 30 3103 HOLD O B EA 107 24 lt Rc72 3 E 2 RC72 1 SIDE Oe lt SELECT a lt RC72 4 100 s lt RC72 7 2 e
29. 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 c bles ensemble en les tordant ou en les enveloppant 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles 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 3 DEFINITIONS 3 1 Warning Label Definitions A Warning Watch Out 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 insulating 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
30. VISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 1 05 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 State 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 a
31. Z ae 27 2 81 LOS res 1 gt gt e lt SMSF 1 WT PRE ee JL __ _ greis E HF STUD Cam ge REMOTE VOLTAGE RC7 2 gt p PS I T OPTION QR WHEN RC7 1 gt Me gt ____ EQUIPPED W METERS As WHEN USED AS SWINGARC OR WHEN EQUIPPED W METERS Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit 4 204 716 B OM 1500 6 Page 25 SECTION 9 PARTS LIST ICS Hardware is common and not available unless listed 803 050 A Figure 9 1 Main Assembly OM 1500 6 Page 26 Item Part No No Description Quantity Figure 9 1 Main Assembly ice PONITUR 159 647 Insulator Motor Clamp 2 VN a 159646 Clamp Motor Base 2 E AAA 159 360 Insulator Screw Machine 0 00 ee RR II 8 TL TT 201 761 Drive Assy Wire S L 4 Roll 1 bu docs etate du ade 201 763 Drive Assy Wire S L 4 Roll Hi Speed W Tach 1 TD ee Uo 143 160 Hub Spindle Assy Consisting Of 2 TUR lt Sedat oe hu 058 427 Ring Retaining Spool 1 Bigs AA act Sted ek dae 180576 2 2081 SUPPO SPOON sica ac
32. bsite 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 reduce magnetic fields in the workplace use the following procedures OM 1500 6
33. c ira bcd rd e oodd dd os ee dete pelos doses recon Quat ae NC pU e 5 2 2 Dangers relatifs au soudage l arc n 5 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 2 4 Principales normes de S curit s tirada abondantes a RS eue SOROR is 8 2 5 Information sur les champs lectromagn tiques ee 8 SECTION 3 DEFINITIONS costosa raras la 9 351 Warning Label Definitions 1 a aida 9 3 2 Rating Label For CE ale e is gor ERI Ot is A AE et 10 33 5yrmbols ANG Dellnillolis 0 am A A A ES 10 SECTION 4 INTRODUCTION ci 552 P euh riore a R TRR RRR RE N RR ad NR RRR N PE 11 Al SPCCIICANOMS oral or ie deans A O A A wate E 11 SECTIONS INSTALLATION 4 5 5 a ER AAA AA AAA DAA AA AAA 11 SS o A O aes 11 5 2 Equipment Connection Diagrams 9555 R 2 R eeni eee nee nent ene rns 12 5 3 Rear Panel Connections And Rotating Drive Assembly 13 5 4 MPN Plug Infor ialiolt 422944 BAENA AAA Ree eae Ieee AAA 14 5 5 Gun Recommendation Table 0 ccc eee hh hrs 14 5 6 Wire Type Size And Feed Speed Capability Table 14 5 7 Installing And Threading Welding Wire 2 2 aaaea 15 5 8 Setting Internal DIP Switches mh 16 5 9 Optional Equipment DIP Switch Settings 17 S
34. ccL 172075 Carrier Drive Roll W Components 2 2 2 2 2 anaana nannan nn 4 4 P TEENS 149 962 Spacer Carrier Drive Roll 2 4 4 ML RE eT Re eel se 149 486 Pin Rotation Arm Rocker 2 2 TE se Ae hot a ods ta 132 750 SAI Pressu Ou odd denen eee ere A Rte a xus st rone ertet wee 2 2 AA 150 520 Spacer Flat Stl 257 ld X 619 Od X 105 UE RR 133 493 Ring Retaining Ext 250 Shaft X 025thk 2 2 p q eee 199 999 PINEDO solia ira as ls 9 M1 101 201230 Motor Gear 1 8hp 24vdc Standard Speed l aise 9 M1 101 201231 Motor Gear 1 8hp 24vdc High Speed A O 153 491 Kit Brush Replacement Consisting Of 17 1 DA tin ds able R 153492 Gap DUST lt ieu pid Seek e RODEO A N As Da 2 A IA 153 493 Brush Carbon tara id die tees rig Paice 2 a ea a bung 184 136 Kit Brush Holder Replacement V eei 2 ls e 155 098 Kit Cover Motor Gearbox Consisting Of loas d HONOR 153550 Cover Motor Gearbox Consisting Of 1 1 VETTURA tees cde nen g 155099 3askeb COVER xus butaca ae eet Beek ode t icm d dae d TORTE 155100 AS A Pip TDI Ue M D ENTUM es Bree D dete Beet tS de a Aes Baas 15403
35. e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Seules des personnes qualifi es sont autoris es a 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 Le 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 Maintenir 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 l
36. e ad ins 602 213 Washer Lock Stl Split 375 Duros 1 TS A IA 602 243 Washer Flat Stl Std 375 1 1 T Y mE 601 966 Screw Cap Stl Hexhd 375 16 X 1 250 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 1500 6 Page 31 2 1290 S Jeu sOy SAUA v uu Buore GZL X ZE 8 MeJosies Z19 v09 M epinc Teemnuy SEZ 970 puy aping ejeipeuueju epino 1 Uy SUreju02 IM 4063 c HZ 90 970 LS 96 cel 090 1951 ZOZ 90 vO ISI 0095 671 Z66094 ww ce E E E N Y LEZ 90 920 ISI 096 CK L 6S0 ISI GOZ 90 GYO ISI LoS GP L 96605 WU g g DUZ 90 vZO LS 196 ce 8S0 ISI 604 90 LEO LS L LoS GP L 96605 UU 76 ULZ 90 20 ISI 096 ce 290 1951 vOZ 90 0170 LS OcS 671 966 09 L ww O S G66 06 WU g Ul 220 890 696 c 9S0 IS 005 6v 802 90 GZO ISI 996 cel 990 ISI 904 90 6 0 LS 669 ESO 6c0 LS OcS 671 966 09 L WU 9 L O67 80 66 OS 687 80 020 ISI 196 cel 890 ISI LOZ 690 2860 LS 169 90 200 LS 615 671 766 051 06 LOL HLS DPL 660SL WU O L 896 cel 090 ISI 000 340 980 LS 00Z 90 960 LS HLS GPL 66 0S4 ww 6 0 969 90 900 ISI HLS GF L 66 0S4 ww 80 UC L 280 1700 ISI HLS GDF L
37. ear combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit HE 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 E 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 guards closed and securely in place e Have only qualified persons remove doors pa
38. ection Diagrams Welding Power Source Contactor Control Power Cord Positive Weld Cable Negative Weld Cable Workpiece Welding Gun Wire Feeder Gas Hose Gas Cylinder and Regulator Customer Supplied ON DOA FW N E Shielding gas pressure not to exceed 90 PSI 620 kPa Ce YE N A o a w S T 803 068 OM 1500 6 Page 12 5 3 Rear Panel Connections And Rotating Drive Assembly gt 1 14 Pin Control Cable 10 Ft 3 0 m 2 Shielding Gas Valve Fittings Requires fitting with 5 8 18 right hand threads Connect customer supplied gas hose 3 Weld Cable Terminal Jumper Weld Cable Weld Cable Drive Assembly Drive Assembly Rotation Knob 8 Rating Label Location NO O 8 To rotate the drive assembly loos en drive assembly rotation knob rotate drive assembly and tighten knob Tools Needed YT 9 16 5 8 in 3 16 in 803 067 802 825 A OM 1500 6 Page 13 5 4 14 Pin Plug Information 7 M Pin Pin Information A 24 volts ac with respect to socket G B Contact closure to A completes 24 volts ac contactor control circuit G Circuit common for 24 volts ac circuit C 10 volts dc input from power source to wire feeder with respect to socket D D Remote control circuit common E O to 10 volts 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
39. ective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection 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 shock sparks and fire hazards Do not use welder to thaw frozen pipes
40. eding stops or feeds erratically during welding Check gun trigger connection See gun Owner s Manual Check gun trigger See gun Owner s Manual Readjust hub tension and drive roll pressure see Section 5 7 Change to correct size drive roll see 5 7 Clean or replace dirty or worn drive roll Incorrect size or worn wire guides Replace contact tip or liner See gun Owner s Manual Remove weld spatter or foreign matter from around nozzle opening Have Factory Authorized Service Agency check drive motor or motor control board PC1 Wire birdnests between feeder and gun Gun liner has to large of diameter opening is clogged or the end of the gun is not close enough to the front set of drive rolls Motor runs slowly Check for correct input voltage Wire feeder power is on displays light up but unit is inoperative Check welding gun trigger leads for continuity and repair leads or replace gun OM 1500 6 Page 22 Notes OM 1500 6 Page 23 SECTION 8 ELECTRICAL DIAGRAM DETACHMENT OPTION OR 10 com PLG117 PLG17 WHEN USED AS SWINGARC RC7 8 S 2 TRIGGER RECEPTACLE Y n B g sj RO7 5 gt gt 1 ERED E E RC11 5 gt COM 3 ZORN D 2I y GREEN an 25 RC6 3 RC11 3 gt gt 2 DORO poy lt pe c se Ua lt RCS RC11 4 WANN 22 y gt BF cy est lt Res 4 y 12 72 ADT Ma ES S 3 ie Df 73 ER AC COMM
41. es 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 Les 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
42. 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 6 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 PIECES 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 e 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 ouie 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
43. he communication error occurs 2 5 sec onds after a loss of communication between the motor and the optional meter board or Dual board The user may continue to weld with this error The error may be cleared by turning power Off waiting a minimum of two seconds and turning power On e The trigger error occurs if the user has the trigger held for more than two minutes with out striking an arc providing current over ride is not enabled or if the user holds the trigger 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 The tach error occurs 2 seconds after the loss of tachometer feedback The user may continue to weld with this error The motor speed is regulated through the monitoring of voltage and current The motor error indicates that the motor has been drawing too much current for too long OM 1500 6 Page 21 7 3 Troubleshooting A Disconnect power before troubleshooting Trouble Remedy Wire feeds shielding gas flows but electrode wire is not energized Check cable connections Check cables for continuity and repair or replace cables if necessary see Section 5 3 Wire feeder is on display does not light up motor does not run gas valve and welding power source contactor do not pull in Check and reset circuit breaker at welding power source Electrode wire fe
44. in the On position e The operator must hold the trig ger for a minimum of 2 seconds but not longer than 6 seconds be fore releasing it Welding will con tinue when the trigger is re leased e To stop welding press the trigger again Ref 803 048 6 5 Voltage Control And Digital Meters 1 Voltmeter Displays actual or preset voltage from welding power source through the 14 pin control cable 2 Wire Speed Meter Displays preset and actual wire feed speed while welding Factory set to display inches per minute If display of meters per min ute is desired see Section 5 9 3 Voltage Controls Use controls to adjust voltage out put of welding power source 7 You can adjust the preset volt age display on the wire feeder to match your power source s display by adjusting P2 on mo tor control board PC101 left side and or P2 on motor con trol board PC1 right side See Section 7 2 for location of P2 Ref 803 065 OM 1500 6 Page 19 SECTION 7 MAINTENANCE 7 1 Routine Maintenance A Disconnect power before maintaining 3 Months Clean and Repair or Replace tighten replace unreadable weld cracked labels terminals weld cable Replace Check Check gas cracked 14 pin cord hose and y bu gun parts fittings 6 Months Clean drive rolls Blow out or vacuum inside During heavy service clean monthl
45. l to half that of the front rolls surface and press gun trigger to feed wire used Also when the gun is installed the against surface Tighten knob so wire liner extending from the back of the gun does not slip Do not overtighten If con should be as close to the drive rolls as tact tip is completely blocked wire should possible without touching 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 S 0627 A OM 1500 6 Page 15 5 8 Setting Internal DIP Switches AP Left Side Motor Remove wrapper Control Board 1 DIP Switch S1 On Motor PC101 Board PC1 ig E f Y gt Setting Current Detect po Override S1 1 Current detect override is used to disable run in when a welding pow Right Side Motor KE K er source is used that doesn t pro Control Board PC1 NE RSS vide current feedback through the Mu A SSS r 14 pin receptacle E Pins F amp H are not present in 14 pin receptacle on machines c that don t provide current 7000 AQ ve back Install wrapper when finished P1 This illustration shows the factory setting of 51 4 In the DIP switch S1 illustrations the elevated slider on each switch is shown in white For example the
46. le 062 Groove 0 1 DN OR ee 132 611 Optical Encoder DISC onc cen ri O 1 Seat A eee 603 115 Weather Stripping Adh 125 X 375 O 1 bec Y ERR 167 367 Spacer Localidad OE ERE POP a IRIS 2 2 ee AAA 168 9259 x DIVE PIMOR sto ts ad il T2 o o ta ta Ne 133308 Ring Retaining Ext 375 Shaft X 025thk Tasas 1 na A Ou IE ghost Cit EE 134 834 Hose Sae 187 Id X 410 Od order by ft 2 Ft 0 6 m AAA 149 959 Fitting Brs Barbed M 3 16tbg X 312 24 dus Wr E A 179265 Adapter Gun Feeder LH 1 1 mU Bima su die ox 179 264 Adapter Gun Feeder RH leia d sagt A 108 940 Screw Cap Stl Hexhd 250 20 X 750 1 A monec E cest ce 604 538 Washer Flat Stl Sae 312 to 1 pond eue eti 151 437 Knob Plstc T 1 125 Lg X 312 18 X 1 500 deciso 1 Kei A ROR ec Gowda ia 151290 Screw Mach Stl Hexwhd 10 32 X 500 ps DO ER 179 277 Cover Drive Roll consisting of 2 d uu 1 APRES ET 178937 Label Warning Electric Shock 2 2 loss 1 oL ee ad aed 601 872 Nut Stl Hex Full Fnsh 375 16 let A WT O bi
47. lir 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 lm 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 malformations cong nitales ou autres probl mes de DES ORGANES MOBILES peuvent provoquer des blessures qu e S abstenir de toucher des organes mobiles tels que des ventilateurs
48. mponents that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Maxstar 150 Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources and Coolers Water Coolant Systems Non Integrated
49. nant 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 a 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 e Couper l alimentation ou arr ter le moteur avant de proc der veillant d ment form de se tenir a 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 i e Installer le poste correctement et le mettre la terre convenablement Ne pas souder dans des endroits situes proximit d op rations de de selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de pulverisation La chaleur et les rayons de provinciales et locales Parc peuvent r agir en pr sence de vapeurs et former des gaz haute zl E ment toxiques et irritants e Toujours verifier la terre du cordon d alimentation V rifier et s assurer e Ne pas souder des m taux munis d
50. nd Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information 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 2005 Miller Electric Mfg Co 1 05 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 GQ Miller
51. nels 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 The user is 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 To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tro
52. nfin s ou l ou 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 g n re 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 v les quipements suivants dans l ordre indiqu 1 un poste souder DC e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et tension constante fil 2 un poste souder DC manuel lectrode les instructions du fabricant concer
53. nic equipment e Be sure this welding machine is installed and grounded according to this manual e lf interference 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 A 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 6 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 Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 we
54. ollowing 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 workpiece is required ground it directly with a separate cable
55. oujours 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 PARTICULES VOLANTES peuvent blesser les yeux pw re e Le soudage l caillement le passage de la piece la brosse en fil de fer et le meulage g n rent des tincelles
56. probl mes de procr ation OM 1500 6 Page 7 2 5 Safety in Welding Cutting and Allied Processes ANSI Standard Z49 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 ins 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 in 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 EMF 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 causera des champs lectromagn tiques II y a eu et il y a encore un certain souci a propos de tels champs Cependant apres avoir examin plus de 500 tudes qui ont t faites pendant une p
57. re 1 bik A 010233 Spring Cprsn 970 Od X 120 Wire X 1 250pld 1 E EET 057 971 Washer Flat Stl Keyed 1 500 dia X 125thk 2 PE cC 010 191 Washer Fbr 656 Id X 1 500 Od X 125thk 2 E T 058 628 Washer Brake oll neta rada a ees 2 A eee 058 4209 x HUD OPOL sti Seanad ria Aa Sake 1 ix dd T 071 730 Tubing STL 875 Od X 12Ga Wall X 2 500 2 e d a e ee abs 135 205 Nut Stl Slflkg Hex Reg 625 11 W Nylon Insert 1 p ome re en EE T41 411 Support SDOOL uda sa eee N A eo es 1 vul qid ma i 208 339 Extension Dual Clamp L H eee 1 2s NO pe 208 338 Extension Dual Clamp R H ees 1 ey resem ane er eee 156 248 Clamp Motor TOD ecards idas 2 Ep AAA 145 639 Strip Buna n 062 X 3 000 X 4 000 Compressed Sht 2 TE TTE 199226 L C 1 eta sos A 134 306 Foot Rubber 1 250 Dia X 1 375 High No 10 Screw 4 Liam cuiii Leia Control Box Refer to Figure 9 2 nono 1 VoL PEOR torts Bek 201 767 Drive Assy Wire R 4 Roll 1 bie Ot Set betes RE 201 769 Drive Assy Wire R 4 Roll Hi Speed W Tach 1 Lee 164059 2 A 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 S
58. riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu Laccumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lec triques a haute fr quence repr sente un risque a la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent a 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 6 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 800 463 6727 ou a Toronto 416 747 4044 site www csa international org t l phone 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 Park 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
59. rocedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION som _3 05 A Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes LN WE 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 A Indique un message de s curit particulier d ELECTROCUTION ORGANES MOBILES et PARTIES CHAUDES Consulter les symboles et les instructions aff rentes ci dessous concernant les mesures prendre pour supprimer S Signifie NOTE n est pas relatif la s curit les dangers 2 2 Dangers relatifs au soudage l arc A Les symboles repr sent s ci dessous sont utilis s dans ce manuel e 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 en e l quipement doit tre hors tension lorsqu il n est pas utilis mati re de s curit indiqu es ci dessous ne constituent qu un e Nepas utiliser
60. switches above are all in the Off position c e O E When DIP switch positions are changed the unit must be turned Off and then On again in order for the new settings Tools Needed to be active DIP switches are only read on power up a 1 4 in Position Settings And Results For DIP Switch S1 On PC1 And PC101 Automatic Run In ON Automatic Run In OFF Current Detect Override ON Current Detect Override OFF Factory Default Factory Default _ _ S1 1 And S1 2 S1 1 And S1 2 S1 1 And S1 2 S1 1 And S1 2 On Run In speed is Off Run In speed is set using On Current detect over Off Current must be detected approximately 1 2 weld wire potentiometer P1 located on Motor ride For welding power from power sources that provide feed speed Board PC1 sources that don t provide current feedback through the current feedback through 14 pin receptacle to go from run in the 14 pin receptacle Run to welding condition Run in is in is inactive active 803 063 Ref 802 944 OM 1500 6 Page 16 5 9 Optional Equipment DIP Switch Settings NT a Remove wrapper HE 1 Digital Meter Board PC60 2 Meter Board Switch S2 Install wrapper when finished Digital Meter Functions i Standard Standard High Speed High Speed eu Motor Motor Motor Motor Inches Minute Meters Minute Inches Minute Meters Minute Tools Needed E C F 4 1 4 in 803 069 OM 1500 6 Page 17 SECTION 6 OP
61. uggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 1500 6 Page 27 ICS Hardware is common and not available unless listed 803 049 C Figure 9 2 Control Box Quantity Item Dia Par o Model No Mkgs No Description D 74S D 74D Figure 9 2 Control Box Figure 9 1 Item 21 em 204 722 Wrapper feeder 1 1 pug dove dades na en ce 134 464 Label Warning General Precautionary Static amp wire Fe 1 1 ts iene de Bene 178 936 Label Warning General Precautionary Wordless Ce Wf 1 1 E NEM A 111 997 Switch Rocker Spst 10A 250vac On Off Visi Red Rock 1 1 nits O ahead PCO uds 220 903 Circuit Card Assy Dual W Program decer 4 PC1 PC101 217 898 Circuit Card Assy Motor Control W Program AA ME TR 030 170 Bushing Snap in Nyl 750 Id X 1 000 Mtg Hole 2 2 D UR 000 527 Blank Snap in Nyl 875 Mtg Hole Black 1 1 CR desea deh E 200 196 Cable Power 11 5ft 8 c 2 14ga 6 18ga consisting of 1 1 T lt TTT 139 041 A A Wise i Sin oo sing aus ME Se 163 519 Cable POM 55h GY Bere AA SG EE mers iA 11 5 Ft 8 5 m Roe Oo co ne wok on 079 739 Conn circ coc clamp str rlf Pass d zou p m PEGT2 402 141162 Housing Plug Pins service kit T uses oi P
62. which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PRO
63. y OM 1500 6 Page 20 7 2 Diagnostics LED3 On Right Side Motor Control Board PC1 LED3 On Left Side Motor Control Board PC101 LED3 On Dual Board PC7O 803 063 A Bea A e LED3 Sequence Indicated Error Left Side Motor Control HELP 11 1 Blink Communication Error Board PC101 HELP 12 2 Blinks Trigger Error HELP 13 3 Blinks Tach Error HELP 14 4 Blinks Motor Error Right Side Motor Control HELP 21 1 Blink Communication Error Board PC1 HELP 22 2 Blinks Trigger Error HELP 23 3 Blinks Tach Error HELP 24 4 Blinks Motor Error Dual Board PC70 HELP 31 4 Blinks Communication Error Since blink On time and blink Off time are equal in a four blink cycle the four blink sequence appears as constant blinking e Error Indications Error conditions are indicated by LED3 on PC1 PC101 PC70 or on display if meter op tion is present To view LEDS turn Off unit re move wrapper and turn unit On LED3 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 e T

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