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Miller Electric D-74DX User's Manual

1. 1 m TTT 208 831 Drive Assy Wire S L 4 Roll Lo Speed W Tach 1 EK 201 763 Drive Assy Wire S L 4 Roll Hi Speed W Tach 1 S GE TT 143 160 Hub Spindle Assy Consisting Of 2 je lt sne ERA Re 058427 Ring Retaining Spool TTT 1 e Suns 180571 ss Shat Support SDOOlL HI e hu eem e e 1 E RUE one 010233 Spring Cprsn 970 Od X 120 Wire X 1 250pld 1 pud E 057 971 Washer Flat Stl Keyed 1 500dia X 125thk 2 OS une 010 191 Washer Fbr 656 Id X 1 500 Od X 125thk 2 Dh TTT 058 628 Washer DrakeGu eee ne 2 iude e sacs 058 428 AUB SPOOL Dr EX xd io UN he hats S Ee S e pA C rw 1 Lo RS 071 730 Tubing STL 875 Od X 12Ga Wall X 2 500 2 muc ERE 135 205 Nut Stl Slflkg Hex Reg 625 11 W Nylon Insert 1 TEL EE T41 411 22 SUBBOU SDOOL Se SR A a a S 1 LS oe eee Du 204 484 Extension Dual Clamp L H 1 To ne ERE 208 338 Extension Dual Clamp R H os reke nre ein LEE ES 1 WS rop EE SU 156243 Clamp Motor Top 2 OSN 145 639 Strip Buna n 062 X 3 000 X 4 000 Compressed Sht 2 TW WEE EC PA NEEN C METEO ne ne wt arn tere Rouse ie a dese te ee a O 1 ADO ater mn 134 306 Foot Rubber 1 250 Dia X 1 375 High
2. Lal 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 0 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 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 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 7 Page 16 5 7 Installing And Threading Welding Wire Install wire guides and anti wear guide Install wire spool Adjust tension nut so wire is taut
3. 2 OO Mec Ge eos 179 277 Cover Drive Roll consisting of 1 TEMPE 178937 Label Warning Electric Shock EN mr 601 872 Nut Stl Hex Full Fnsh 375 16 1 TO TERCERO HERES 602 213 Washer Lock Stl Split 375 1 SO EE 602243 Washer Flat Stl Std 375 1 S rare EE 601 966 Screw Cap 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 1500 7 Page 41 2 1290 S Jeu SIIOH SAUA v Yum Buoje GZL X ZE 8 MeJosies Z L9 v09 M epinc JB9AHUV SEZ 970 puy aping ejeipeuueju epino 1 uv SUIB1UOO 1 4063 c HZ 90 970 LG L 96 cel 090 ISI ZOZ 90 Evo ISI 0095 DL 266 OGL ww et N K LEZ EGO 920 ISI 096 CK L 650 ISI GOZ 90 GYO ISI LeS GP L 966051 WU g g 60 90 720 LS L 196 CCL 8S0 ISI 604 90 LvO LS L LoS 671 966 0SI UU 76 ULZ 90 620 ISI 096 cel 290 ISL YOZ 90 0170 LSL 06095 671 966 OGL ww OC 966 OS Ww g Ul 620 990 656 CE L 9S0 ISI 005 6v 9804 90 GZO ISI 996 CE L GSO ISI 90 90 6 0 ISL 669 90 6c0 LSL OcS 671 966 OGL WW 9
4. 1 ope Overlay Front PARRE HT 1 ox Circuit Card Assy Switches 1 Panel Pc Card Display W Program 1 Switch Rocker Spst 10A 250vac On Off Visi Red Rock 1 Circuit Card Assy Dual W Program 1 Circuit Card Assy Motor Control W Program 2 Bushing Snap in Nyl 750 Id X 1 000 Mtg Hole 3 Blank Snap in Nyl 875 Mtg Hole Black 1 Cable Power 11 5ft 8 c 2 14ga 6 18ga consisting of 1 E e sil TTT 1 a Gable POW AA RN dune 11 5 Ft 3 5 m SOONNNCIEC ee e E une Stilt EE 1 Housing Plug Pins service kit 1 Housing Plug Pins Skts service kit 1 Housing Plug Skts service kit 1 Nut 750 14 Knurled1 68dia 41h Nyl 2 Valve 34VDC 1way 750 14 Thd 2mm Orf 100PSI 2 Bushing Snap in Nyl 1 375 Id X 1 750 Mtg Hole 2 Stand off Support Pc Card 312 375w Post amp lock 43 17 M uses E PIRE 1 Item No Dia Mkgs Part No Description Figure 11 2 Control Box Continued Panel EO dd a Tae e E Nameplate Lower Nameplate Lower CE Version Switch rocker spdt 15A 12V on off on S
5. 1 un poste souder DC tension constante 17 Indique des instructions sp cifiques Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e Eneffectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humidi
6. 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 and 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 O 2007 Miller Electric Mfg Co 2007 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
7. 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 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 OM 1500 7 Page 3 1 4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California t
8. NUR JE 55 Be 8 RC113 2 2 2 2 m E 10 10 E a RC11 5 gt gt R715 pa i E dE gem ed L 73 Jj AC COMMON XD RX syo UN ae ciL PEN Sos 5 lt l lt 006 3 RC11 1 2 RC71 1 RC78 1 2 2 24 17 A Cae DOR 3 lt 006 2 RC11 2 gt IX fex 74 lt lt RC71 2 RC78 2 yy E E 2 2 1 lt Oe ra d lt Rce 1 AC COMMON 2 CONTACTOR m E a RC1 1 Zeg RC798 1 6076 6 gt gt M 3 l 3 S z Re1 2 20 a Ro 6 yy CURRENT FEEDBACK daa EIN a IG VOLTAGE FEEDBACK p i GE EE NE 65101 e CURRENT FEEDBAEK 37 ar RC76 2 E VOLTAGE FEEDBACK RC76 3 222 MS A gt lt lt RC4 1 E E 5 RTE 4 gt gt WHEN USED RC3 2 gt gt lt RC75 2 AS SWINGARC AK Wer z PUR E A S A pos ES 4 7 6 lt gt 8 gt lt RC4 4 2 RC3 4 RC75 4 82 Qe PC101 5 35 A 3 WAT BLK 29 GLK 29 RC7 9 gt gt lt RC70 1 ES lt Ss 2112 lt lt RC4 3 MOTOR BOARD LEFT re 2 1 A e RC1 PLG101 RC7 10 2 7 M RC70 2 S RC3 PLG103 2 d RC4 PLG104 Rc10 5 gt 112 PC70 T 168 YA 3 188 Baz RC5 PLC105 E 3 lt lt 3 Se lt n RC6 PLG106 RC10 1 S102 DUAL CONTROL BOARD 1 D AA O 35 70 ALY 70 RC7 PLG107 RC70 PLG70 2 2 lt 24 A lt RCs 2 SER S S RCIO PLGMO wenn p AE 727 RC71 PLG71
9. de ao 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 nottouch 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 If 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 following equipment in order presented 1 a semiautomatic D
10. onds after a loss of communication between the motor and the Front Panel board or Dual board The user may continue to weld with this error 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 Indicates a tachometer error TCH2 Indicates a tachometer error 1 LED3 On Right Side Motor Control Board PC1 2 LED3 On Left Side Motor Control Board PC101 3 LED4 On Dual Board PC70 gt There is a two position DIP switch 57 located on motor con trol boards PC1 and PC101 These switches are factory set in the off position and must re main in that position for the unit to operate correctly 803 063 A MTR1 Indicates a motor error MTR2 Indicates a motor error e 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 e The motor error indicates that the motor has been drawing too much current for too long 8 3 Diagnostics For User Defined Options 1 Front Panel 2 Front Panel Board PC20 User Defined Shutdown Error Messages Additional hardware required for
11. DSS 9 is recommended for this application OM 1500 7 Page 29 8 2 Diagnostics 4 LE Note The error messages are shown on the upper and lower displays to indi cate specific errors Ex planations are in the text below COM1 Indicates a com munication error Right Side Motor Control Board PC1 COM2 Indicates a com munication error 2 y E GAS I UM b da A E nF Y va Indicates a trigger error TRG2 Indicates a trigger error Dual Board PC70 LED3 Related Error Indications Error conditions are indicated by LED3 on PC1 PC101 and LED4 on PC70 To view LED3 4 turn Off unit remove wrapper and turn unit On 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 OM 1500 7 Page 30 Indicates a COM3 communication error 1 blink Communication Error 2 blinks Trigger Error 3 blinks Tach Error 4 blinks Motor Error e The communication error occurs 2 5 sec
12. PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 2007 01 Owner s Record
13. de Global Engineering Documents t l phone 1 877 413 5184 site Internet 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 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 Protec tion Association P O Box 9101 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 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 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 sou dage 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 exa min 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 exposi
14. le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talliques en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de maniere incorrecte ou impropre constitue un danger Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e SiSoler 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 e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu
15. 16 5 7 Installing And Threading Welding Wire 17 5 8 Setting Internal DIP Switches e bet ee RET LEE RARE RUE astral ones ide 18 5 9 Power Source Selection Menu 19 SECTION 6 OPERBALTNION kou nn o ace Ra coed e pe E or yia RE Sets tenes 20 Gals Operational T us doo o e de o i nC Rt m dress Ue Nm ate onn a S nr Nom a Ra 20 p 2 POWEr e ie os iuc OL ac rtc Ea OR Kaa Cue dod e e e e dee a ow ee c lese ee alee 20 6 3 Leim Right oelecE oOWIICli is oR de ts RIO E RARE MERGER En So ERE e XR a 20 6 4 dog PUGS WIE a diese aie em AA dan RU RUNE Red qudm uode da qx OU 21 6 5 ront Panel GOonDlrols usui qeu d nrc ie na eh nara teams N GENE CR E CER Pe ee aE res 22 5 5 JProgramil ushiBUlloDt ua o ecc db Lou pug seco en og es Ng ere teehee Er 23 6 7 IBDDSICDISDIAV nace eic cen Oc C HIC alae cedat DAC nea aUe ut scum MED a i 23 638 Lower DISDlay osi oes hus ERES SER ORE SERES ebbe bes OR ee epu e eas 24 6 92 SUD Push BUD unt ru dana turc E dE Se PS cha piae du aun dudas mud 24 OO AIS else ER 25 6 11 S6quence Push Bullon NEEN ANT RER Re RR ER RO RUE CR CO E E ACRI a NE 25 5 12 AuMillany MER EE 26 SECTION 7 SETTING SEQUENCE PARAMETERS LTE x x x x x e rm rrr RR EE 29 7 1 Sequence Parameters In A Program 29 SECTION 8 SETTING DUAL SCHEDULE PARAMETERS cence eee eee nnn 29 8 1 Optional D
16. 7 amp 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 KF 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 are only read on power up 1 bibi 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 7 Off 8 Off Standard 7 On 8 On Low Speed speed motor 50 780 inch Motor 19 300 inches per 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 OM 1500 7 Page 18 5 9 Power Source Selection Menu Non CE Model Shown Program Volts Time T Kl e Wire Speed Amps e Start 2 Crater Trigger Hold Pre Postflow Dual Schedule L Sequence Power Source Upper Display Lower Display Voltage Range EE EE E For any power sources not listed pick a matching voltage range or see Sec 5 12 to set Vmin and Vmax 1 Upper Display 2 Lower Display gt When the feeder is turned on the Power Source Selection Menu allows the operator to se le
17. 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 Table 11 1 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 Motor runs slowly Check for correct input voltage Wire does not feed until trigger is pulled but continues to feed after trigger is re leased and trigger hold is not on Check for a short between welding gun trigger leads and weld cable Repair short or replace welding gun Gas valve in feeder is rattling loudly along with possible erratic or slow wire feed speed Check for a short between welding gun trigger leads and weld cable Repair short or replace welding gun 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 7 Page 32 Notes OM 1500 7 Page 33 SECTION 10 ELECTRICAL DIAGRAM DETACHMENT OPTION OR WHEN USED AS SWINGARC PLG117 PLG17 Rc7 8 gt gt COM 2 Rc7 5 gt gt Ee 1 Rc11 5 gt gt COM nt 962 HIRD ng 22220 RC11 4 gt gt Ch
18. air supplied respirator MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment 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 K
19. 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 re specter 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 TINCELLES VOLANTES ris quent de provoquer des blessures EN e Porter un cran facial pour prot ger le visage el les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable P Q S e LES CHARGES LECTROSTATI QUES 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 de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s app
20. 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 button 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 trol 1 Sequence Push Button 2 Sequence Push Button LED 3 Welding Sequence LEDs Weld Start Time Time Crater Time Preflow Time Postflow AA 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 mod
21. 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 7 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm 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 Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd 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 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Feder
22. flammables away 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 ix dei 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 4 3 STATIC ESD can damage PC boards MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place gt D 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 reconnecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine replacement parts from the manufacturer 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
23. grounding of the workpiece 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 e Wear a safety harness if working above floor level Keep all panels and covers securely in place 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 HOT PARTS can cause severe burns Do not touch hot parts bare handed 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 iiim OM 1500 7 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Bre
24. ls ja RC4 2 gt ES lt RE RUM A 6S1 Re4 1 gt J PEL gt 5B 56 WHEN USED AS SWINGARG er a EE SE gt 77 PUR RE AT HET E va lm d JE E g E e RC5 3 T gt 090 lt i lt gt 33 E a RC5 2 em a WI aT el o Rcs 1 gt e EP 2 1 PRE L c uec E RC15 gt gt HF STUD Q Q GA DE a o Non S N S 9 nm OPTIONAL d 45 AN N g RC26 1 gt DE DE tc FS101 LEFT RC26 2 ee NOTE FS1 ERR OPT 2 FS101 ERR OPT 1 RC24 1 gt FS1 RIGHT RC24 2 gt e T lt lt lt lt lt lt ZX lt lt lt lt lt dn KE PC21 INTERFACE DISPLAY lt lt lt SWITCH BOARD BOARD lt lt lt RC21 PLG21 K RC27 PLGZ7 lt lt 204 144 C OM 1500 7 Page 35 SECTION 11 PARTS LIST gt Hardware is common and not available unless listed 803 052 A Figure 11 1 Main Assembly OM 1500 7 Page 36 Item Part No No Description Quantity Figure 11 1 Main Assembly PEE PONITUR 159 647 Insulator Motor Clamp I 2 VN AES ditt anta RUE d 159 646 Clamp MotorBase 2 E ENEE 159 360 Insulator Screw Machine 8 TL EET 201 762 Drive Assy Wire S L 4 Roll W Tach
25. ori ginal 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 simulta neously press the Program Sequence upper display and Setup push buttons to exit the re set 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 If 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 upper 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 settings correspond to arc voltage obtaine
26. peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil A Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE DECHARGE ELECTRIQUE peut a entra ner la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et les circuits internes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil
27. sequence Any combina tion of programs may be used Trigger Pro gram Select cannot be used while welding or with Dual Schedule Example If programs 1 and 3 have a mini mum of 0 2 seconds of preflow time clicking the trigger will toggle between programs 1 and 3 Trigger Dual Schedule Select DUAL allows the operator to switch between paired sched ules programs 1 2 3 4 5 6 or 7 8 with the gun trigger but only while welding This fea ture cannot be used with Trigger Hold or Dual Schedule To end the weld the trigger must be released for 0 4 seconds Example when welding with this feature en abled in program 1 if you release re trigger and hold again within lt 0 4 seconds the ac tive program will switch to program 2 If the previous sequence is repeated the active pro gram will switch back to program 1 This cycle can be repeated for the entire weld Process Select Process selection indicated by PROS in the upper display is set to either VOLT or TRIM in the lower display Each program can be selected be be a MIG program indi cated by VOLT or a pulsing program indi cated 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 fro
28. 01 Symboles USesS 2 0x de nai A X C oe OR ios NR ce Dod do t Cea Poe a t ied a los 5 2 2 Dangers relatifs au soudage l arc n 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements nn 8 2 5 Principales normes de s curit 9 2 6 Information EMP s tais L ausum Rue ARA RO ks RRR Eee EI ee Dot edu Dee EDU DU rs OR de Sacr 9 SECTIONS D FINITIONS 1 seau beo mto Pe wee bo OVES Veo vem pbi cate 11 3 1 Warning Label Definitions 11 332 Rating babel FORCE Products ii rs ad E Ree ont ara Lic Doo kame SS ok 12 3 3 WEEE Label For Products Sold Within The EU 12 3 4 Symbols And H RIT ien TTT 12 SECTION s INTRODUCTION eee e nen EAA E T Ne x Oa re T n ue 13 e En Dee TTT 13 SECTIONS INSTALLATION oe oD se ee nes ne cute ste E UPS NAN a NR RE N N N ATN 13 5 Site Selection TTT 13 5 2 Equipment Connection Diagrams ii K ERE LERNER ERE ERR RR SERENE KR AVA 14 5 3 Rear Panel Connections And Rotating Drive Assembly 15 5 4 14 Pit reg nie 16 5 5 Gun Recommendation Table ses dunes Re Re e Cm RRR EROR UN NOR Rr RU ds 16 5 6 Wire Type Size And Feed Speed Capability Table
29. A EDO a eic Le a zehn Enea des deter a BR ce Ec Rite bee eR ane PTT E 184 136 Kit Brush Holder Replacement 1 T PREIS 155098 Kit Cover Motor Gearbox consisting of 1 Der 153550 Cover Motor Gearbox consisting of 1 MODERNER EN WARE 190 099 2 MOdSKeL COVEN Ee Ree bre a Aa sta mette cer fi Hm 155 100 lt SSCTEW COVER LEE diee papers C dates aie ee tata lt 5 EE 1304 0931 22800 LOCAUNG WEE ree 133 493 Ring Rtng Ext 250 Shaft Grv X 025thk DEE 203 642 Pressure Arm R amp Vert L 4 Roll consisting of d OA E E AE 203 631 Pressure Arm S L amp Vert S R 4 Roll consisting of 1 oe sI eae a ea 203 641 Washer Flat Indicator Spring Tension 2 UD 182415 Pin Golter Hall oes AE RR EUR Eu Dus dnd pet ed Suri wer roe 1 ie KC GE 203 640 Knob W Extension Short Pressure Arm 1 OM 1500 7 Page 40 Item Dia Part No Mkgs No Description Quantity Figure 11 3 Drive Assembly Wire continued TED PP TT ods 182 156 elle IS RNN 2 UN o ed SR 192 1959 248 ODA a a ne eg nc nt ME WAONA WA 2 te t lt ed dr coter 132 746 7 2 BUSHING OONO EE 2 rk de eee 209099 EE DI DG REENEN 1 fen en Aie Neel casts ih ee 203032 ack Garler SIVAN zu addas RE eid ata A Ba eas nus 1 mu cp 133 739 Washer Fl
30. AGNETIQUES peuv ent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction 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 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 sou dage les manipuler avec pr caution e Prot gerles bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber 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 soude
31. C 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 gt Indicates special instructions e STD ei This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards 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 Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill 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
32. Duty Cycle Degree Of Pr i Gd H Z Hertz gt Program olo Wire Feed Jog gt Output RE Trigger d i Line Connection Set Up Sequence eis Trigger Hold On Trigger Hold Off Purge din Press To Set Start Crater Time t 5 Preflow Time e to Postflow Time EN Read Instructions b Increase 1 Primary Current Rated Current U 2 Load Voltage A U 1 Primary Voltage gt Dual Schedule OM 1500 7 Page 12 Q7 amp Sdo w 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 Optional Low Speed 19 to 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 4 equipment when it could tip e A 1 Wire Feeder 2 Rubber Feet Choose slot that allows all rubber feet to sit securely on top of welding power source 3 W
33. L O67 80 v66 OS L 687 80 020 ISI 196 cel 890 ISI 102 690 Z 0 LG L 169 90 ZZO LG L 615 6 766 051 061 LOL 8lG6 660SL UUOI 896 cel 090 ISI 000 6020 980 LS L UUZ 90 9600 LS L 8lG6 66605951 ww GO 969 690 SCO ISI HLS GF L 66 0S4 ww 80 UC L 280 1700 ISI HLS GDF L 66 OGL WU9O Ut 960 600 140 LS L 996 CCL YSO LS L COZ 90 800 ISI 615 Gr L 8 0 ISI 869 90 Hou 01126 9AMQq 9AMQq 9AMQq JUN Uone a 23 2 OOdD O 3JAOOHDPIA JAOOu5 JAOOHD A m SHY SPIND SIM PUY 10H 9AHQ LLL 9IdEL 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 2007 Equipment with a serial number preface of LH 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 effect
34. No 10 Screw 4 Aa ns a ie ou Control Box Refer to Figure 11 2 1 DR EE YI 201 768 Drive Assy Wire R 4 Roll W Tach 1 EEN eren 208 830 Drive Assy Wire R 4 Roll Lo Speed W Tach 1 TN NETTE 201 769 Drive Assy Wire R 4 Roll Hi Speed W Tach 1 vid Wi p Sale 164059 x OS 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 7 Page 37 gt Hardware is common and not available unless listed Item Dia No Mkgs Re P use EN 2 TT tre 4 ET css 5 PCO20 O OI ees 7 POZO ius 8 PC1 101 Re a EIO haana A ler le da haa Bek tee E E TA EE 15 PLG12 G PLG52 A PLG74 TO ss 17 GS1 101 jl RENE ERE KO aoe eh cn FO PO PTO OM 1500 7 Page 38 Part No 134 201 803 051 C Figure 11 2 Control Box Description Quantity Figure 11 2 Control Box Figure 11 1 Item 21 Wrapper Feeder 1 Label Warning General Precautionary Static amp wire Fe 1 Label Warning General Precautionary Wordless Ce Wf 1 Panel Pc Card Front Consisting Of
35. OM 1500 7 204 129H 2007 07 Processes MIG GMAW Welding Flux Cored FCAW Welding Gas And Self Shielded Description i ES Wire Feeder OWNER S MANUAL File MIG GMAW ES a 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 E 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 Uyo udhia ete jue ere ex e i i 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 Wl 00012000 of reliable service with proper maintenance And if for some reason the unit nee
36. Pte Res IS lt Rcs 1 RC11 PLG111 RC72 PLG72 RO73 PLG73 gm de RC74 PLG74 44 RC75 PLG75 RC10 6 gt RC76 PLG76 HF STUD Q RS RC77 PLG77 RC10 2 gt RC78 PLG78 RC79 PLG78 REOS LEADIS 751 MA 0 pe x RC73 2 AS lt RC72 3 ep yA RC73 3 gt gt MMMM 27 cow 7 Oo RC72 1 _10 MM amp WARNING Do not touch live electrical parts MI lt RC73 19 gt Disconnect input power or stop 20 engine before servicing lt RC72 4 Do not operate with covers removed 3100 ELECTRIC Have only qualified persons install zT lt RC72 7 SHOCK HAZARD use or service this unit ch 10 lt RC72 2 474 lt RC72 8 HF STUD PK RC85 14 PIN D D PLG12 JO amp Si pe pep MMC RC77 2 o e EL ge SA Mee 77 B e A CONTACTOR C lt RO74 5 lt YELLOW CURRENT FEEDBACK RC74 1 E VOLTAGE FEEDBACK C748 C lt AAA BE HOV RC74 2 Figure 10 1 Circuit Diagram OM 1500 7 Page 34 lt RC27 8 7g lt RC27 10 TAD AXD 13 PC1 DETACHMENT OPTION OR WHEN USED AS SWINGARC MOTOR BOARD le 00 N TRIGGER m Q 2 amp Sie RECEPTACLE RC1 PLG1 a goa T E a la nuls RC3 PLG3 RC amp 4 gt lt 9 f2 gt g A AD A ee RC6 3 gt 21 19 GREEN 43 27 ZEN 3 RDG PLGB R EL oM AA LM RC7 PLG7 Reged is 19 AN pa Ig 1 RK RC10 PLG10 gt AS TIS zi RC11 PLG11 d i
37. Quantity OM 1500 7 Page 39 gt Hardware is common and 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 Dia Par No Mkgs No Description Quantity Figure 11 3 Drive Assembly Wire Figure 11 1 Item 4 livrets en 010 668 Screw Cap Stl Sch 250 20 X 1 500 4 PR 172075 Carrier Drive Roll W Components 4 PE EN 149 962 Spacer Carrier Drive Roll 4 M EEN 149 486 Pin Rotation Arm Rocker 2 TE ORNARE 132 750 Zu Atm Pressure s 3o e te C ert e ee LA 2 D o ER 150 520 Spacer Flat Stl 257 Id X 619 Od X 105 2 ANR MUA KUA ENS 133 493 Ring Retaining Ext 250 Shaft X 025thk 2 OE oo 133 350 ose lt Tae CC ee Sew Re A RL ake Bh 1 9 M1 101 201 230 Motor Gear 1 8hp 24vdc Standard Speed 1 9 M1 101 201 231 Motor Gear 1 8hp 24vdc High Speed optional 1 Se Oe ae MES TOT ees 207 892 Motor Gear 1 8hp 24vdc Low Speed optional 1 153491 Kit Brush Replacement consisting of 1 SL K lads EE ow 199 492 unis CAD BIS us e er Rai aen UR DR NA N Qo UR o dn N EX ax aM bs aL EE 159493 us BUS
38. al 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 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 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 Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som 2007 04 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes Symboles utilis s 2 1 DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas
39. at Buna 375 Id X 625 Od X 062thk 2 Re Ma 203 637 Knob W Extension Long Pressure Arm 1 21 PC51 151 201225 Circuit Card Digital Tach consisting of 2 ER PLG5 181204 Connector amp Sockets 604 311 Grommet Rbr 250 Id X 375mtg Hole 062 Groove 1 RC ein dead ade ed 132 611 Optical Encoder DISC seers ra ood nae hab WA 1 dant E E ie 603 115 Weather Stripping Adh 125 X 375 d WI a cA Dd ine 167 387 Spacer et ee eph NS in eee ed i 2 De ni mu dua E 106629 ty DIV PINON LS SN MST AA 1 EE LL 133 308 Ring Retaining Ext 375 Shaft X 025thk 1 ME T 134 834 Hose Sae 187 Id X 410 Od order by ft 2Ft 0 6 m ho Won MU BEC 149 959 Fitting Brs Barbed M 3 16tbg X 312 24 1 Exc E 179265 Adapter Gun Feeder LH en 1 REE a EE 179 264 Adapter Gun Feeder RH 1 Loop n 108 940 Screw Cap Stl Hexhd 250 20 X 750 4 auc ET 604 538 Washer Flat Stl Sae 312 1 mci 151 437 Knob Plstc T 1 125 Lg X 312 18 X 1 500 1 OC NN EET 151 290 Screw Mach Stl Hexwhd 10 32 X 500
40. athing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside 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 and the manufacturer s instructions for metals consumables coatings cleaners and degreasers 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 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 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 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 Wear an approved welding helmet fitted with a proper shad
41. ct 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 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 may 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 Po
42. d 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 setting VMIN and VMAX will override the default power source settings gt 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 On 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 al lows 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
43. ds 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 e 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 2005 04 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 tele Symbol CS ARE a sera co e al deese due iR TT 1 1525 GAVE E e tegt a EE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 2 4 185 Principal Safety Standards s sosseua a cec sex rac Er eo aee ru ba tentait ved nan dodo 4 1262 EMF IBTOTITIS e see Le i Det a D deo cn nne Do Ko te ah ra Nu na oot Mee dio 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2
44. e being locked out of the auxiliary menu indicated by LOCK in the lower dis play The power may be cycled to continue 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 SECTION 7 SETTING SEQUENCE PARAMETERS 7 1 Sequence Parameters In A Program ICS For more information on Sequence Push Button see Section 6 11 If time is set to zero in Weld Sequence Parameters sequence welding continues until un trigger is released If time is set to zero in any timed sequence is skipped la mmm lx ooo X Setting available Weld Time Burnback Time COW Vos Preflow Run InStart Weld Crater Postflow Sequence End Trigger Trigger Pressed Released 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 C7 Will not function with trigger hold and dual schedule A
45. e 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 Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Es 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 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 Do not weld on closed containers such as tanks drums or pi
46. e souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES SA LETES peuvent provoquer des bles sures dans les yeux 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 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 LES CHAMPS M
47. e 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 postflow 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 7 Page 25 6 12 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 NP AREE mw 7 Wire Speed Amps N 6 O O JO Q ON Start Crater Trigger Hold Pre Postflow 6 Dual Schedule 9 3 HL o Sequence Adjust Setup CE Models OM 1500 7 Page 26 6 12 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 control can be used to change the unit to WIPE ON When WIPE ON is set if the
48. ear 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 HF 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 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 MIG Guns TIG Torches and 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 Miller s 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 Trailblaze
49. ed 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 1 Jog Purge Switch 2 Adjust Control 3 Gun Trigger Receptacle Ref 803 053 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 OM 1500 7 Page 21 6 5 Front Panel Controls Nameplate For Non CE Models See Section 6 7 See Section See 6 6 Section 6 8 L Start Crater Pre Postflo Section Section Section 6 11 6 10 6 9 Nameplate For CE Models 4 See Section See ee Section 6 6 A See Section Section Section Section 6 11 6 10 6 9 OM 1500 7 Page 22 6 6 Program Push Button Non CE Models Program 6 7 Upper Display gt To set the correct voltage range for a particular power CE Models E JL source see Section 5 9 for power source selection menu or Section 6 12 for V Min And V Max adjustments OA Volts eV Y 4 a L T 1 Upper Display The upper display shows vo
50. eep 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 near 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 If 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 FLYING SPARKS can cause injury e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep
51. elles 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 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 Etat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants A Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation OM 1500 7 Page 8 Pour les moteurs essence Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl 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 com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1
52. er plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 1500 7 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coupe l alimentation e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces DES PIECES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures b LES FUM ES ET LES GAZ peuvent tre dangereux FA N Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais seurs e T
53. es interf rences e Le rayonnement haute fr quence H E peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e 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 t
54. go est 312 353 2220 site Internet www osha gov 1 Garder les cables ensemble les torsader les scotcher ou les recouvrir d une housse 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 soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 1500 7 Page 9 OM 1500 7 Page 10 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 plug or power before working on machine 2 Breathing welding fumes can be haza
55. hold function to work Once the trigger hold func tion is in effect the wire feeder will stay On un til 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 function 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 trigger 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 rele ased 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 or Trigger Dual Schedule to be enabled or disabled The upper display shows TSEL Lower dis play shows OFF or PROG or DUAL The Adjust Control is used to select OFF or PROG or DUAL Trigger Program Select PROG allows the operator to select programs during preflow 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
56. ime 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 lease trigger to clear error OM 1500 7 Page 23 6 8 Lower Display TT T Non CE Models OA Mr Wire Speed e ud OM Wi olo 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 9 Setup Push Button 3 4 Trigger Hold Dual Schedule 1 n 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 U
57. ire Spool Reels 4 Gas Cylinder w Hose And Regulator Customer Supplied gt Shielding gas pressure not to exceed 100 PSI 689 kPa 5 Welding Power Source 6 Running Gear 7 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 9 for V Min And V Max adjustments Wire feeder shown is representative only and does not reflect actual unit Ref 803 053 OM 1500 7 Page 13 5 2 Equipment Connection Diagrams Welding Power Source Contactor Control Power Cord Positive Weld Cable Negative Weld Cable Workpiece Welding Gun Wire Feeder Gas Hose O co DOA E Go N Gas Cylinder and Regulator Customer Supplied gt Shielding gas pressure not to exceed 100 PSI 689 kPa OM 1500 7 Page 14 803 073 5 3 Rear Panel Connections And Rotating Drive Assembly a PA 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 Oo MO 8 To rotate the drive assembly loos en drive assembly rotation knob rotate drive assembly and tighten knob Tools Needed 9 16 5 8 in 3 16 in 803 067 802 825 A OM 1500 7 Page 15 5 4 14 Pin Plug Information
58. ive date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped 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 Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Y
59. lammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud 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 Surveiller tout d clenchement d incendie et tenir un extincteur proximit 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 par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz OU va peurs inflammables vapeur d essence par exemple e Brancherle c ble 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 provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l 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 d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant d
60. ltage 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 dii 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 T 41 Time We 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 f the unit is displaying a welding sequence that can be timed the welding time display mode is entered by pressing the upper dis napere 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 t
61. m 0 to 250 ipm Locks are program dependent and wire speed is independent 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 OM 1500 7 Page 27 6 12 Auxiliary Menus Continued 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 in the lower dis play 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 On 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 Notes OM 1500 7 Page 28 quence if shielding gas flow to the gun is inter r
62. o cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 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 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 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
63. ode 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 2007 04 Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text DANGER Indicates a hazardous situation which if NOTICE Indicates statements not related to personal injury 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 persons should install operate maintain and repair this unit During operation keep everybody especially children away
64. pes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline 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 OM 1500 7 Page 2 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 Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT 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 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
65. r 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 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
66. r 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 cifique 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 lorsque 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 suffi samment de personnes pour soulever et d placer les bouteilles 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 cu rit 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 Nepasinstaller l appareil proximit de pro duits 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
67. r 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 votre 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 sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 1500 7 Page 6 LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchaui fement ou un incendie Avant de commencer le soudage v rifier 6 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 soigneusementavec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inf
68. ravailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux e sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant I soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ge
69. rdous 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 7 Page 11 3 2 Rating Label For CE Products ICS For label location see Section 5 3 J dr lt C U 24 VA 1 50 60 Hz Us 100V 1 750 A X100 ST 178 794 A 3 3 WEEE Label For Products Sold Within The EU Do not discard product where ap plicable with general waste Reuse or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collec tion facility Contact your local recycling office or your local distributor for further information 3 4 Symbols And Definitions gt Some symbols are found only on CE products Amperes V Volts t Alternating Current X
70. rocher des points de coincement tels que des rouleaux de commande m OM 1500 7 Page 7 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 per sonnes ou toute pi ce m canique en enga geant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures a e Sabstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion e Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e 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 Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N tiliser que les pi ces de rechange recom mand es par le constructeur e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE RAYONNEMENT HAUTE FR QUENCE H E risque de provoquer d
71. se the Adjust control to change OM 1500 7 Page 24 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 f the unit is in a welding state that does not involve feeding wire the unit displays 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 12 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 er 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 displa
72. t d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e Nutiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e lsoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccord
73. the factory set automatic run in speed is selected 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 disabling of the run in feature When the lower display indicates OFF run in is dis abled 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 Burn back settings like run in settings are pro gram specific The active program is dis played in the Program display and can be ad justed see Section 6 6 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 trigger hold to work when the trig ger is released the trigger hold function must be on For example if a trigger hold delay time of 2 0 seconds is defined the operator must hold the trigger for at least 2 seconds be fore releasing it in order for the trigger
74. these to be functional If OPT1 and or OPT2 are enabled without additional hardware setup the following error messages will be displayed on the front panel meters OPT1 and or OPT2 must be dis abled ICS Refer to Section 6 12 for cor rect setup procedures 803 071 Indicates a User Defined Option Error SECTION 9 MAINTENANCE amp TROUBLESHOOTING 9 1 Routine Maintenance Lx Maintain more often during severe conditions 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 e gun parts fittings 6 Months Blow out or vacuum inside During heavy service clean monthly Clean drive rolls OM 1500 7 Page 31 9 2 Troubleshooting A Disconnect power before troubleshooting Trouble Remedy Wire feeds shielding gas flows but elec trode wire is not energized Check interconnecting cord connections If secure check cord for continuity and repair or replace See Sections 5 2 and 5 3 Wire feeder is on meter s do 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 feeding stops or feeds er ratically during welding Check gun trigger connection See gun Owner s
75. tion aux champs magn tiques et champs lectriques 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 ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes LAW 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd 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 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet 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 de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux regionaux le t l pho ne de la r gion 5 Chica
76. ual Schedule Switch Diagrams rese 29 cB Ls Tate i EE NR EE 30 8 3 Diagnostics For User Defined Options 31 SECTION 9 MAINTENANCE amp TROUBLESHOOTING OL 31 9 1 JRoutine Maintenance EE 31 9 2 MGUSA NO scivit dE ra de eu EU EE 32 SECTION 10 ELECTRICAL DIAGRAM Sa erm ram AAA ad an mm acm rmn E cnt aa 34 SECTION 11 PARTS LIST e Pe ENES REESE RUE de eae rare in e eds d 36 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 D 74 DX conforms to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC Electromagnetic Compatibility EMC Directive 89 336 EEC Machinery Directives 98 37 EEC 91 368 EEC 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 C
77. upted 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 OPT2 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 hold the last weld information for 5 seconds following weld 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 When the Setup button is pressed again the menu repeats Code Upon leaving the auxiliary menu the user is asked if a password code indicated by CODE 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 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 befor
78. wer 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 12 OM 1500 7 Page 19 SECTION 6 OPERATION 6 1 Operational Terms The following is a list of terms and their definitions as they apply 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 Ref 803 072 6 3 Left Right Select Switch 1 Left Right Select Switch Pressing the Left Right Select switch allows the operator to choose which side of the units con trols will operate Depressing the Left or Right Gun Trigger also allows the operator to enable the con trols on that side of the unit Ref 803 053 OM 1500 7 Page 20 Jog Purge Switch 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 trigger is still activat
79. when wire feed stops Install drive rolls Pressure Indicator i err im CY Ae E Tools Needed diis m 3 16 5 64 in E p 15 16 3 8 in Drive Rolls Back Of Gun End Of Liner CS For best wire feeding performance be CS For soft wire or small diameter stainless gt F To adjust drive roll pressure hold nozzle sure that the outlet cable has the proper size liner for the welding wire size being used Also when the gun is installed the liner extending from the back of the gun should be as close to the drive rolls as possible without touching Install gun Lay gun cable out straight Cut off end of wire Push wire through guides up to drive rolls continue to hold wire Press Jog button to feed wire out gun steel wire reduce drive roll pressure on the rear roll to half that of the front rolls about 2 in 51 mm from nonconductive surface and press gun trigger to feed wire against surface Tighten knob so wire does not slip Do not overtighten If con tact tip is completely blocked wire should slip at the feeder see pressure adjust ment above Cut wire off Close cover Ref 156 929 A Ref 150 922 Ref 156 930 S 0627 A OM 1500 7 Page 17 5 8 Setting Internal DIP Switches NE x 1 DIP Switch S1 D DU 2 DIP Switch S4 Not For Customer Use S DIP switch 51 allows the user to make a num ber of choices affecting unit operation Defining Motor Speed S1
80. witch rocker spdt 15A 12V on off on W leds Knob Encoder 1 670 dia x 250 id push on w spring Nameplate Upper ix Nameplate Upper CE Version 27 RC13 113 048282 211989 RCPT W SKTS service kit Fitting w screen Quantity 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 Mkgs PLG6 106 PLG72 PLG10 110 PLG4 104 PLG11 21 71 111 PLG1 77 78 79 101 SE PLG3 75 76 103 PLG51 deed PLG7 27 67 107 PLG73 PLG17 70 PLG117 Part No 115 094 130203 115092 136 810 131 055 202 592 115 093 174824 115 091 148 439 158719 165404 Description Harness Connectors Receptacles Housing Plug Skts Housing Plug Skts Housing Plug Skts Housing Plug Skts Housing Rcpt Skts Housing Plug Skts oon D oum e PTS A service kit service kit service kit service kit service kit service kit Housing Plug Skts service kit Housing Plug Pins Skts service kit Housing Plug Skts service kit Housing Plug Pins Skts service kit Housing Plug Skts service kit Housing Rcpt Skts service kit
81. y will read dashes for amperage readings below the amperage threshold prior to arc initiation CE Models e When the 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 the 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 10 Adjust Control HI Adjust Non CE Models 6 11 Sequence Push Button Start Crater 9 Pre Postflow di R R Sequence Non CE Models 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

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