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Miller Electric and DS-74DX16 User's Manual

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1. 1 hal OE PLG73 148439 Housing Plug Pins Skts service kit 1 E PLG17 70 158 719 Housing Plug Skts service kit 1 ET PLG117 165 404 Housing Rept Skts service kit 1 OM 1500 14 Page 37 Hardware is common and not available unless listed 30 ST 142 306 H Figure 10 3 Boom Assembly OM 1500 14 Page 38 Quantity Item Part Model No No Description DS 12 DS 16 Figure 10 3 Boom Assembly Figure 10 1 Item 13 eames 1 010313 Pin Cotter Hair 072 X 1 437 4 4 XE 2 010910 Washer Flat Stl Sae 375 6 6 T 3 079 622 Washer Shld 381 Id X 750 2 2 ee 4 079621 Pulley V Sgl Grv 7 750dia X 8 000p X 625 Bore 2 2 uu 5 079667 Pipe Plstc 500 X 133 750 2 0 Duns 5 080812 Pipe Plstc 500 X 181 750 0 2 Ls et 6 079632 Bolt U Stl 250 20 X 875 Wide X 1 375 Deep 8 10 V iN Z uuu 079 665 Guide be ru rac brain eru a T ves OBOB s Guide Wire 4 sal aa Dane US 2 m 8 079664 Guide Wire
2. Fig 10 3 Boom Assembly 1 1 14 RC37 137 047 637 Connector amp Sockets consisting of 2 5232 inso PLG45 145 131 203 Housing Plug Pins service kit 2 2 digne PLG44 144 167 640 Housing Plug Pins Skts service kit 2 2 Piston PLG46 146 115090 Housing Plug Pins service kit 2 2 po rm 203 314 Cable Trigger 20 In Boom Detach consisting of 2 22 FEN EE 115 094 Housing Plug Skts service kit 2 2 ELE EDE 080 328 Rept W Skts Free Hanging 2 2 EE RE HE 079 531 Conn Circ Cpc Clamp Str RIf Size 11 4530d 2 2 TERE Me AE IE 604 571 Cable Port No 18 4 C Type sjo nprnjktre 2Ft jm 605 227 Nut Nyl Hex Jam 750npst 2 2o 17 GS1 101 228 035 Valve 3AVDC 1way 750 14 Thd 2mm 100PSI 2 iuda PLG4 104 136 810 Housing Plug Skts service kit 2 2 SR RE Er 139 813 Cover Protector Motor T und ert RE A 139 816 Panel Encl Cover ERE PO sus rames x ra WA 159 647 Insulator Motor Clamp 2 sir 2 ARS IE 1
3. Trigger Hold Dual Schedule Adjust Setup Wire Speed Amps N 2 Power Source Deltaweld 452 Deltaweld 302 Deltaweld 652 Dimension 302 Dimension 452 Dimension 652 Dimension 1000 XMT 304 XMT 456 Invision 354MP Invision 456MP Invision 456P PHOENIX 456 SUMMIT ARC 1000 SUM 1000 Vmin 225 Upper Display Lower Display dELT 452 dELT 302 dELT 652 diM 302 diM 452 diM 652 diM 1000 XMT 304 XMT 456 1354 MP 1456 MP 1456 P PHX 456 Vmin 10 Vmin 10 Vmin 10 Vmin 10 Vmin 10 Vmin 10 Vmin 10 Vmin 10 Vmin 10 Vmin 10 Vmin 10 Vmin 10 Vmin 10 Voltage Range Vmax 38 Vmax 32 Vmax 44 Vmax 32 Vmax 38 Vmax 65 Vmax 60 Vmax 35 Vmax 38 Vmax 35 Vmax 38 Vmax 38 Vmax 38 Vmax 44 For any power sources not listed pick a matching voltage range or see Sec 4 12 to set Vmin and Vmax 1 Upper Display 2 Lower Display E When the feeder is turned on the Power Source Selection Menu allows the operator to se lect a default power source Selecting a default power source automatically sets the correct Vmin and Vmax set tings for adjusting the output voltage of the power source First Time Feeder Is Turned On The feeder automatically goes into the Power Source Selection Menu The feeder displays dELT on the Upper Display and 452 on the Lower Display meaning that a Del taweld 452 is the default power Source
4. 1 OPTIONAL 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 14 Page 42 Table 10 1 Drive Roll and Wire Guide Kits Wire Size 3s 5 V GROOVE U GROOVE VK GROOVE UC GROOVE 3 3 6 5 2 4 Roll Drive 4 Roll Drive 4 Roll Drive 4 Roll Drive Fraction Metric m Kit Roll Kit Roll Kit Roll Kit Roll 023 025 in 0 6 mm 150 993 149518 151024 087 130 030 in 0 8 mm 150 993 149 518 151025 053695 035 in 0 9 mm 150993 149518 151026 053 700 151036 072000 151 052 132 958 040 in 1 0mm 150993 149518 161189 053 696 045 in 1 1 1 2 mm 150 994 149519 151 027 053697 151037 053 701 151053 132 957 151070 083 489 052 1 3 1 4 mm 150 994 149 519 151028 053698 151038 053 702 151054 132 956 151071 083 490 418 ni 1 6mm 150995 149520 151029 053699 151039 053706 151055 132 955 151072 053 708 068 072 in 1 8 mm 150995 149 520 151 056 132 959 5 64 in 079 2 0mm 150995 149 520 151040 053704 151 057 132 960 151 073 053 710 3 32 in 094 2 4 mm 150 996 149 521 151041 053703 151 058
5. 206 765 Panel Front 1 ET oa 206 771 Nameplate Miller Lower 1 22 82 102 200295 Switch Rocker Spdt 15A 12V On Off On 2 23 8100 201641 Switch Rocker Spdt 15A 12V On Off On W leds 1 ial bona 213 134 Knob Encoder 1 670 Dia x 250 Id Push On W Spring 1 veu a ce DE 207 745 Nameplate Miller Switch 1 Dia Part Mkgs No Description Quantity Harness Connectors Receptacles saute PLG6 106 115094 Housing Plug Skts service kit 1 he tas PLG10 110 130 203 Housing Plug Skts service kit 1 Hermann PLG72 115092 Housing Plug Skts service kit 1 SERRES PLG4 104 136 810 Housing Plug Skts service kit 1 PLG11 21 71 111 131 055 Housing Rept Skts service kit 1 PLG1 77 78 79 101 202592 Housing Plug Skts service kit 1 cuis PLG3 75 76 103 115093 Housing Plug Skts service kit 1 AE S PLG51 174 824 Housing Plug Pins Skts service kit 1 Tor PLG7 27 67 107 115091 Housing Plug Skts service kit
6. 3 16 5 64 in 3 8 15 16 in Install wire spool Ad just tension nut so wire is taut when wire feed stops Pressure Indicator Scale Install wire guide Cm 2 Pressure C Adjust Drive Rolls d Gun Cable End Of Liner N ft m NONCONDUCTIVE NONCONDUCTIVE SURFACE SURFACE No Wire Slip Wire Slips EF Be sure that outlet cable has proper For soft wire or small diameter stainless gt To adjust drive roll pressure hold nozzle size liner for the welding wire size steel wire reduce drive roll pressure on about 2 in 51 mm from nonconductive When installing gun position liner the rear roll to half that of the front rolls surface and press gun trigger to feed wire extending from outlet wire guide as against surface Tighten knob so wire close as possible to drive rolls with does not slip Do not overtighten If con out touching tact tip is completely blocked wire should slip at the feeder see pressure adjust Install gun Lay gun cable out straight Cut off ment above Cut wire off Close cover end of wire Push wire through guides up to drive rolls continue to hold wire Press Jog button to feed wire out gun 803 196 152 648 A 803 020 802 966 Ref 137 391 A 802 954 Ref S 0627 A OM 1500 14 Page 17 4 12 Setting
7. c e AS HO E RUE PS D lt LANGE EOM pong OM 1500 14 Page 32 Figure 9 1 Circuit Diagram A DETACHMENT OPTION OR 2 lt lt RC7 8 Ret WHEN USED AS SWINGARC MOTOR BOARD lt lt RO7 5 RIGHT 8 Be gle RECEPTACLE RC1 PLG1 E Ten E EE PRED ie 72 lt lt RCM 5 RC3 PLG3 RC6 4 gt gt lt 9 lt gt 9 gt SA lt 4 Hi Rc6 3 gt piik EEN 5 19 gt P sy APO og 20 ALU 20 20 7 ce ROMA RC6 2 gt gt 13 213 22 27 lt 2 RC7 PLG7 19 IYAK RC6 1 gt lt 14 lt SES lt 1 RC11 PLG11 E a 2 a ots pal lt lt RCI 1 amp amp 4 2 gt gt lt 5 s I 25 lt lt RC1 2 cst E lt lt 803 5 E peat gt Des MM 5 a SP gt lt lt RC3 1 WHEN USED E AS SWINGARC lt RC3 6 E RO4 4 gt 2046600 Psa AK 4 gt lt lt RC3 2 I OI Le RO3 4 4 3 gt I ce BES Is gt 3224 E dle MOG 213 lt lt RC10 5 RC5 3 gt gt 60 lt 3 E S 3568 S S 45V a RC10 1 x 2 pU x qe ugs eg 8 PURGE 8 lt lt Re10 4 rest EE EE 51 mr BRP m we Sts REIS 55 28 orsu o e e m r4 a S X 8 E SEES AAA OPTIONAL Somma L 1 25 N NR RC26 1 gt gt 54 eo D lt lt
8. 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 cable de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en 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 En cas 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 de 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
9. 4 Swivel Assembly Insert into pipe post Lubricate swivel 5 Safety Collar Tools Needed SP 3 4in 152 268 B OM 1500 14 Page 11 4 2 Installing Control Box And Adjusting Tilt Tools Needed C I F 3 8 in SS B 1 Weld Control 2 Bracket 3 Screw Bracket and screws are installed onto bottom of control at factory 4 Swivel Loosen screws Place control on swivel and slide forward Tighten Screws 5 Tilt Bracket 6 Rear Pivot Screw 7 Front Screw Loosen rear pivot screw Remove front screw Pivot control down ward to desired viewing angle Re place and tighten front screw Tight en pivot screw 803 192 4 3 Installing Boom And Reel Support A c Tools Needed SP 3 8 3 4 in 1 Swivel Plates 2 Yoke Remove hardware from swivel plates and yoke 3 Boom Set boom into swivel as shown 4 Yoke Pin Install pin through yoke Install cot ter pin and spread ends 5 Bolt Install bolt washers and nut Tight en hardware and back bolt off one half turn 6 Locking Knob Install locking knob but do not tighten 7 Reel Support Install reel support ST 153 170 A OM 1500 14 Page 12 4 4 Installing Wire Guide Extension Wire Guide Fitting Bolt Monocoil Liner Wire Guide Extension Tighten bolt to secure liner in wire 4 guide fitting Do not overtighten bolt and crush liner RP POND Repeat pr
10. OM 1500 14 Page 28 7 2 Diagnostics SN 1 LEDSOn Right Side Motor Control Board PC1 2 LED3 On Left Side Motor Control Board PC101 3 LED4 On Dual Board PC70 There is a two position DIP switch S1 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 Left Side Motor Control Board PC101 ERR ERR ERR ERR EF Note The error messages are shown on the upper and lower displays to indi cale specific errors Ex planations are in the text below COM1 TRG1 TCH1 MTR1 Indicates a com munication error Indicates a trigger error Indicates a tachometer error Indicates a motor error Right Side Motor Control Board PC1 ERR ERR ERR ERR COM2 TRG2 TCH2 MTR2 Indicates a com munication error Indicates a trigger error Indicates a tachometer error Indicates a motor error Dual Board PC70 ERR COM3 Error Indications Error conditions are indicated by LED3 on PC1 PC101 and LED4 on PC70 To view LEDs 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
11. duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste N LES TINCELLES VOLANTES ris quent de provoquer des blessures 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 LES CHARGES LECTROSTATI QUES peuvent endommager les o circuits imprim s AS So N 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 9 provoquer des blessures gt 5 i Ne pas s approcher des organes mobiles Ne pas s approcher des points de coincement tels que des rouleaux de commande OM 1500 14 Page 7 LES FILS DE SOUDAGE peuvent provoquer des blessures Ne pas appuyer sur la g chette avant d en avoir recu l instruction 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 AJ e S abstenir de toucher
12. lt RC75 3 4 eg gt g gt lt RAM RC3 4 gt gt 2 lt lt RC75 4 52 OES PC101 ae oe sd lt R43 RO7 8 gt gt JF lt lt RO70 1 t MOTOR BOARD LEFT m RC1 PLG101 RC7 10 gt gt lt lt RC70 2 8 RC3 PLG103 2 a RC4 PLG104 RC10 5 DE 112 m let 168 Mi 108 RC5 PLG105 B 3 lt lt 3 lt gt 3 gt lt lt RC6 PLG106 Re10 1 5 26 48 S102 DUAL CONTROL BOARD N 1 gt ee 25 2 7 ZU 77 RC7 PLG107 RC70 PLG70 2 2 RC5 2 EM SES SES 72 SUE RCIO PLGMO y 727 RC71 PLG71 BER M ef sis IN Rs RC11 PLG111 RC72 PLG72 RC73 PLG73 RC74 PLG74 p RC75 PLG75 RC10 6 5 RC76 PLG78 HF lt lt 15 RC77 PLG77 RC10 2 22 oe RC79 PLG79 RCSS LEAD9S e AS COMMAND RC73 3 gt gt RC73 2 gt gt FAK AS EK lt RC72 5 m a RC73 9 gt gt 27 Oe lt RC72 1 RC73 10 22 224 WARNING Do not touch live electrical parts SIDE n T SELECT 4 Disconnect input power or stop 40 engine before servicing lt RC72 4 Do not operate with covers removed 5100 ELECTRIC Have only qualified persons install 23 lt RC72 7 SHOCK HAZARD use or service this unit 104 lt Rc72 2 E 47 Ld lt RC72 8 HF STUD 2 lt lt Ross 14 PIN p PLO12 51 Ac Ef o NNOL AMA 2 lt lt 2 lt lt RC77 1 p lt lt lt p etur CURRENT FEEDBACK e RON VOLTAGE FEEDEMEN ee
13. 139 600 Hose Gas 2 0 ASE en cn 139 599 Hose Gas cele as hate ean naci ta RR a 0 2 EE 600 324 Cable Weld Cop Strd No 4 0 order by ft 26Ft 30Ft par d oe ut EE NE 602 243 Washer Flat Stl Std 375 8 8 cuo aer 602 213 Washer Lock Stl Split 375 4 4 SE IA deed e eee EE ded 601 872 Nut Stl Hex Full 375 16 4 4 IE ANB 080 947 Bracket Spring Retaining 1 0 breui ei e sit 151 626 Bracket Spring Retaining 0 1 RE cte RA 132 053 Screw Cap Stl Hexhd 375 16 X 1 500 Lg 4 23 4 TOS en Fig 10 5 Support Hub amp Reel d 2m o1 GATE 149 838 Pipe Post 4ft W Base 1 0 zo ES si amas te 149 839 Pipe Post 6ft W Base 1 0 mue 078 264 Pipe Post 4ft W Base Q 1 ues eee 079 216 Pipe Post 6ft W Base Q 1 AE 075 078 Pipe Post 4ft W O Base Or qd vei MEE RES 079 217 Pipe Post 6ft W O Base T ms VS
14. 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 0 4 seconds the active program will switch to program 2 If the pre vious 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 se lected be be a MIG program indicated by or a pulsing program indicated by TRIM Range Locks Range locks are indicated by LOCK in the upper display for wire speed or LOCK in the lower display for voltage range In a MIG pro gram the voltage range lock ranges from 0 to 10 volts In a pulse program the trim range lock ranges from 0 to 100 The wire feed speed range lock ranges from 0 to 250 ipm Locks are program dependent and wire speed is inde pendent from voltage or trim Wire Feed Speed Units Wire feed speed setting indicated by WFS in the upper display is set to IPM inches per minute or MPM meters per minute This setting is independent of the program se lected OPT1 e f the Setup push button is pressed the unit allows OPT1 to be disabled or enabled The upper display shows OPT1 Lower dis play shows or The Adjust
15. Inlet 2 2 iud 9 139 633 Liner Monocoil 3 32 1 8 Wire X 15 687 2 2 den TO 159999 Boom Dual zv iere eene ee I eR Gades ever Ake Dd 10 4 160018 Boom Dual ERR data eru eser a OU suas N Has 11 080947 Bracket Spring Retaining 1 0 SRE EE 11 151 626 Bracket Spring Retaining 0 1 12 073742 Pin Clevis 750 Od X 2 156 Lg 1 1 am ters 18 073744 Clevis 812 Yoke 6 062 Lg 750 16Thd 1 1 MEE 14 079029 Nut Stl Hex Full Fnsh 750 16 2 2 uus 15 075 462 Shaft Boom Counterbalance 1 1 vuv 16 602250 Washer Flat Stl Sae 750 2 2 s us 17 079020 Nut Stl Hex Elastic Stop 750 16 1 1 ARE 18 155335 Pipe Blk 8 000 X 875 D 1 uu 19 149858 Spring Cprsn 3 750 Od X 625 Wire X 36 000 1 0 puteis 19 151625 Spring Cprsn 3 750 Od X 640 Wire X 36 000 0 1 Papx 20 150258 Retainer Spring
16. Internal DIP Switches P 1 DIP Switch S1 uN 2 Switch S4 Not For Customer Use DIP switch S1 allows the user to make a num ber of choices affecting unit operation Defining Motor Speed S1 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 Setting DIP switches allows the feeder to display the proper wire speed Setting the DIP switches will not change the speed range of the motors E 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 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 803 198 Position Settings And Results For DIP Switch S1 7 Off 8 Off Standard speed motor 50 780 inch es per minute or 1 2 19 8 meters per minute 7 Off 8 On High speed motor 92 1435 inches per minute or 2 3 36 4 meters per minute OM 1500 14 Page 18 4 13 Power Source Selection Menu Non CE Model Shown Program Start Crater Pre Postflow Lou Seguence Volts Time sec
17. Needed Increasing Spring 1 Locking Knob Tighten knob to prevent boom movement Loosen knob to allow boom movement Change knob po sition to limit upward movement Pull boom down slightly and re move safety collar Boom should balance in any position from hori zontal to 60 degrees above hori zontal If necessary adjust boom as follows 2 Threaded Rod 3 Jam Nut Loosen jam nut and turn threaded rod until boom balances Tighten jam nut Be sure several full threads are through yoke to prevent boom falling 4 Yoke 5 Safety Collar Retain safety collar for use in disas sembling or moving boom Decreasing Spring P 13 8in Pressure For A Heavy Pressure For A Gun Lighter Gun ST 142 599 C 4 9 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 4 10 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 3 To 19 8 mpm Standard All 3 32 To 7 64 in 2 4 To 2 8 mm 50 To 700 ipm 1 3 To 17 8 mpm Standard All 1 8 in 3 2 mm 50 To 300 ipm 1 3 To 7 6 mpm ii All 023 To 5 64 in 0 6 To 2 mm 92 To 1435 ipm 2 3 To 35 6 mpm OM 1500 14 Page 16 4 11 Installing And Threading Welding Wire Re Tools Needed E
18. Q Miller OM 1500 14 207 499H 2007 07 Processes MIG GMAW Welding Flux Cored FCAW Welding Gas and Self Shielding Submerged SAW Welding Description EE Wire Feeder Use with CV Power Sources DS 74DX Swingarc Visit our website at www MillerWelds com DS 74DX12 and DS 74DX16 OWNER S MANUAL File MIG GMAW m 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 n U E PEENI 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 Working as hard as you do every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installati
19. 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 Arc Time e If the Setup push button is pressed the unit displays arc time in hours Arc time is indicated by the Program display showing HR Arc time is shown in the lower display Cycles e f the Setup push button is pressed the unit displays the number of cycles Arc cycles are indicated by the Program dis play showing CL The arc cycle count is shown in the lower display Run In e f the Setup button is pressed the unit allows setting the run in modes The run in modes are program specific Each program may be set to its own run in mode The upper display indicates RUNI The lower display indicates AUTO meaning the factory set automatic run in speed is se lected Pressing the lower display button allows a manual setting the run in wire speed Speed may be adjusted from 1096 to 10096 of weld wire speed Pressing the lower display button allows dis abling of the run in feature When the lower display indicates OFF run in is disabled OM 1500 14 Page 25 5 12 Auxiliary Menus Continued 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
20. Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HFUnits 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 6 Months Batteries 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 Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting no
21. 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 throughthe list of power sources by using the Adjust control After se lecting a power source the operator has three seconds to change to a different power source or begin welding After making a power Source selection the operator may press the Program Button to avoid having to wait the three seconds When turning off the feeder the de fault power source will be retained If voltage settings have already been set with the Vmin and Vmax in the Auxiliary Menu selecting a de fault power source with the Power Source Selection Menu overrides the Vmin and Vmax voltage set tings Next Time Feeder Is Turned On The feeder will display the last se lected default power source The operator has three seconds to se lect another power source or press the Program Button to exit the Pow er Source Selection Menu Disabling The Power Source Selection Menu Once the default power source has been selected the Power Source Selection Menu may be disabled using the Auxiliary Menus See Section 5 12 OM 1500 14 Page 19 SECTION 5 OPERATION 5 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 b
22. d viter tout contact physique avec la pi ce couper ou le sol 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 Sil tilisation 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 talliques telles 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 1 un poste souder DC tension constante F Indique des instructions sp cifiques e 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 dui
23. 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 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 N tiliser 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 fa on 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 isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 1500 14 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces DES PIECES CHAUDE
24. 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 r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de Vous 5 Connecter la pince sur la pi ce aussi pr s qu
25. mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 1500 14 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 surchau fement ou un incendie Avant de commencer le soudage v rifier 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 inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e 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
26. ni de flammes 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 o 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 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 MAGNETIQUES peuv ent affecter des implants m dicaux 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 aff
27. repeatedly until welding time is the active parameter in the upper The upper display shows voltage 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 display At idle the upper display toggles between showing weld voltage or weld time with subsequent presses of the up per display push button 4 Volts LED 5 Time LED The LEDs below the display illuminate to in 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 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 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 14 Page 22 5 8 Lower Display al OH 1 Lower Display The lo
28. to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY S 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 equipmentto 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 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
29. 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 SECURITE LIRE AVANT UTILISATION fre_som_2007 04 A 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 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 A 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 rente
30. 1 1 Pudet 21 024605 Bearing Ball Thr Sg Row 750 X 1 625 X 625 1 1 22 075101 Nut Stl Hex Special 750 16 X 1 250 1 1 m 23 079030 Washer Lock Stl Ext Tooth 750 1 1 send 24 174 754 Base Swivel Boom consisting of 1 1 D ME 080 157 Fitting Grease 1 8npt 1 1 bth en 25 174688 Bracket Mtg Control Tilt 1 1 EE 142 804 Label Swingarc Caution Heavy Spring 1 1 EER EE abate 134 327 Label Warning General Precautionary d 1 fu ys 26 073666 Bolt Mach Stl Hexhd 750 16 X 2 750 1 1 igit 27 047 224 Knob T bar 500 13Thd 1 1 TER 28 602246 Washer Flat Stl Std 500 1 1 Ale 29 010498 Bushing Snap in Nyl 625 Id X 875mtg Hole 1 1 e 30 139818 Guard Motor Protector 1 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Rep
31. 132 961 151 074 053 709 o in 2 8mm 150 996 149 521 151042 053705 151059 132 962 151075 053711 1 8 in ios mn 3 2mm 150997 149 522 151043 053707 151060 132 963 151076 053712 Each Kit Contains An Inlet Guide Intermediate Guide And 045 233 Antiwear Guide With 604 612 Setscrew 8 32 x 125 Along With 4 Drive Rolls 2 Kits Required For Dual Models S 0549 D OM 1500 14 Page 43 Notes H OF WELDING TECHNOLOGY Start Your Professional 400 trade square East Troy Ohio 45373 OWeF 80 000 trained Welding Career Now 1 800 332 9448 www weldina ora since 1930 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 C 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
32. 4 Page 31 SECTION 9 ELECTRICAL DIAGRAM PLO117 PLG17 RC7 8 gt gt a gt 2 gt RC7 5 gt gt y gt 1 gt RC11 5 gt gt 226 13 IER DETACHMENT OPTION OR 811 5 gt gt WHEN USED AS SWINGARC RC11 4 gt gt OD TRIGGER 8 5 a g 8 Rens OM 1e w RC11 5 RC71 5 aS 20D ac 46 Sy ED S os 8 4 gt lt lt mm XD RX gp FIN ge 25 cioe ERE 15 25 A lt pos 3 RC11 1 gt gt lt lt RC71 1 RC78 1 gt gt POR ZAAG 2 gt 2 lt ze lt 13 lt 2 ES 13 gt 1 lt I lt RC6 2 RC11 2 gt gt p 14 lt lt RG71 2 RC78 2 gt gt 23080 23 AW 23 1 gt 1 lt lt 14 lt gt 14 gt lt RC 1 B h 1 1 gt gt COMMON 2 lt lt Rc79 1 RC76 5 gt gt 2204070 2 a 8 1 2 gt gt 2 40 7 lt lt Rc79 2 Rc78 1 S gt AENT Me ORANGE Js VOLTAGE FEEDBACK 2 BE gt 5 gt lt lt RC4 2 RC76 6 gt gt gt gt CO VACTUR JE lt lt RC75 5 RC76 2 gt gt 55701 1 gt gt CURRENT 37 RO 5 1 VOLTAGE FEEDBACK _ 39 RC76 3 gt gt H ciet eN S lt RA RC3 6 gt gt lt lt RC75 6 5I RC76 4 gt gt WHEN USED RC3 2 gt gt lt lt RC75 2 AS SWINGARC 54 12 ze ze RC3 3 X
33. 5 Pin Cotter Hair Tz 203 640 Knob W Extension Short Pressure Arm Tess Tf asd Case 182 156 Spring GPS soc Rue a MERI 2 2 18 55 neve 182 155 ar SPM uera etos wee DO dd PS ER So ied ee Vox 2 522 TO EE ed sus bei 132 746 Bushing Spring 2 2 20 EER EER EE 2039 6338 gt va Shaft Spring s LE a d erus 05 208 632 ies Carrier Shaft css clau Gd qued iT ber deu ae Tod PRET OE wg 133 739 Washer Flat Buna 375 Id X 625 Od X 062Thk Dita es ID RE N 203 637 Knob W Extension Long Pressure Arm 1 1 24 PC51 151 201225 Circuit Card Digital Tach consisting of lisses 1 SENSE PLG5 131 204 Connector amp Sockets 1 1 ER ER 604 311 Grommet Rbr 250 Id X 375Mtg Hole 1 1 AE EE 132 611 Optical Encoder Disc 1 usus SR EEEN 603 115 Weather Stripping Adh 125 X 375 1 1 20 ER acest 134 834 Hose Sae 187 Id X 410 Od order by ft 2 Ft PTS EN ser Lis 149959 Fitting Brs Barbed M 3 16Tbg X 312 24 Tia rd EE N NE 179 265 Adapter Gun Feeder Lh 1 1 28 toties 179 264 Adapter Gun
34. 59 646 Clamp Motor Base 2 Bare PARIS 159 360 Insulator Screw Machine 8 8 29 stress gau viens ed 156 243 Clamp Motor Top 2 2 24 etude 145 639 Strip Buna Compressed Sheet 062 4 000sq 2 vax 2 EE OE a 134 834 Hose Sae 187 Id X 410 Od order by ft 3Ft 20 208 944 Drive Assy Wire Rh Vertical 4 Roll W Clamp amp tach Fig 10 4 1 1 AE TEE 208 945 Drive Assy Wire Rh Vert 4 Roll Hi speed W Cl amp tach Fig 10 4 1 1 PT vor EEN 157 295 Guide Monocoil 2 xvi 2 ie vec cin irn 604 612 Screw Set Stl Sch 8 32 X 125 Cup Point 4 4 DO NL HE ED 082 050 Liner Monocoil Inlet Wire CORRE EE 201 776 Drive Assy Wire L Vertical 4 Roll W Clamp amp tach Fig 10 4 1 1 BOE 201 777 Drive Assy Wire L Vert 4 Roll Hi speed W Cl amp tach Fig 10 4 1 1 TE EE EE 149 322 Clamp Hose 405 485clp 4 4 Gil ete EE 211 989 Fitting W Screen 2 dus OPTIONAL Note When ordering Control Box contact factory service department for proper number To maintain the factory original performance of your equipment use o
35. 93493 FAX 44 0 1204 598066 www MillerWelds com 2 Miller
36. 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 or Off The Adjust Control is used to select either On or Off OPT2 is a second input that may be used with an external device such as a gas flow Switch to end the weld sequence The gas flow switch may be used to stop the weld se quence if shielding gas flow to the gun is inter rupted A closed set of contacts between pins 1 and 2 of RC24 on Interface Board PC20 will allow feeder to operate normally Opening the contacts will stop the weld sequence and dis play 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 DFF or HOLD in the lower display When HOLD is selected the unit will hold the last weld information for 5 seconds fol lowing weld termination If any front panel push button is pressed or if the Adjust control is activated the
37. Feeder Rh 1 1 20 beoe 108940 Screw Cap Stl Hexwhd 250 20 X 750 4 4 90 i ess 604 538 Washer Flat Stl Sae 312 diss d Ql cec EE 151437 Knob Plstc T 1 125 Lg X 312 18 X 1 500 Bar lis S EET UR 151 290 Screw Hexwhd Slt Stl Slffmg 10 32 X 500 OE EE Dong MEE 179 277 Cover Drive Roll consisting of ls LE RE EN S EIE 196 956 Label Warning Electric Shock And Pinch 1 1 BA MdL e Mes 601 872 Nut Stl Hex Full 375 16 NES ee eer 602 213 Washer Lock Stl Split 875 1255 DO ef eei eer ida 602 243 Washer Flat Stl 375 Tv EE MEE 601 966 Screw Cap Stl Hexhd 375 16 X 1 250 Ts do 167 387 Spacer Locating 2 Le c aeo EES 168 825 Drive Pinion 40t 24p 376 Bore dd sn 133 308 Ring Retaining Ext 375 Shaft X 025Thk 122 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 14 Page 41 Hardware is com
38. RC27 3 FS101 7 K RO27 2 o ET Ed lt lt RC27 8 RC26 2 p NOTE FS1 ERR OPT 2 lt lt RC27 10 pA F8101 ERR OPT 1 24 1 gt FS1 RIGHT o RC24 2 gt SEK amp RR SEK lt lt PC21 INTERFACE DISPLAY SWITCH BOARD BOARD lt lt lt lt RC21 PLG21 ERK RC27 PLG27 lt x SEK lt _ lt lt _ lt SEK amp lt _ lt X lt lt P 204 144 C EK lt Ld OM 1500 14 Page 33 SECTION 10 PARTS LIST Figure 10 1 Main Assembly OM 1500 14 Page 34 Quantity Item Dia Part Model No Mkgs No Description DS 12 DS 16 Figure 10 1 Main Assembly EE EE See Note Control Fig 10 2 1 1 eB auk d ee 201 319 Cable Interconnecting consisting of 2 0 RE MEE EI 201 320 Cable Interconnecting consisting of 0 22 PLG37 38 137 138 047 636 Connector amp Pins 2 vu eue Uere nie 079 739 Connector Circ Clamp Str Sz 17 20 Amp 206322 2 2 2 EE 163 520 Cable Port No 18 14 8 C order by ft 17Ft 21Ft xcu ERE
39. S 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 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 D LES FUMEES ET LES GAZ peuvent tre dangereux I 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 A 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 Travailler 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 r
40. Setup Push Button 22 eer exa ER teow Dn e ex der out Oda CERE EE ae ERE Rs 23 5 10 Adj st Control ES BREER BERE UE ERR EON E EN E 24 5 11 Sequence Push Button oie sci EE RE DE ES oe Yu de REN QUEE EE QUER CREER 24 5212 Auxiliary Menus a oer ater aves ER EE nn QUEE UPS Ame EN E 25 SECTION 6 SETTING SEQUENCE PARAMETERS 27 6 1 Sequence Parameters In A Program 27 SECTION 7 SETTING DUAL SCHEDULE PARAMETERS 28 7 1 Optional Dual Schedule Switch Diagrams 28 7 2 DiagnostiGs OR OR hn Soe re ee Raine Vi EE La 29 7 3 Diagnostics For User Defined Options 30 SECTION 8 MAINTENANCE amp TROUBLESHOOTING 30 8 1 Routine Maintenance ices cia end Rear ek aere dae ee YR REA E Re 30 8 2 Troubleshooting sic ex RE da are Re rh a Le eo ee ren ne Vna 31 TABLE OF CONTENTS SECTION 9 ELECTRICAL DIAGRAM SECTION 10 PARTS LIST OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _2007 04 A Protect yourself and others from injury read and follow these precautions 1 A A 1 Symbol Usage DANGER Indicates a hazardous situati
41. 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 commu nication error existed the light would blink four times for the motor error Since blink On time and blink Off time are equal in a four blink cycle the four blink se quence appears as a constant blink 1 blink Communication Error 2 blinks Trigger Error 3 blinks Tach Error 4 blinks Motor Error e The communication error occurs 2 5 sec onds after a loss of communication be tween the motor and the Front Panel board or Dual board The user may continue to weld with this error e The trigger error occurs if the user has the trigger held for more than two minutes with out striking an arc providing current over ride is not enabled or if the user holds the trigger past the postflow phase in a timed weld This error also occurs if the trigger is held when the feeder is powered up The er ror may be cleared by releasing the trigger 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 OM 1500 14 Page 29 7 3 Diagnostics For User Defined Option
42. ack 1 201 228 Cable Power 16 5 8 c 2 14ga 6 18ga consisting of 1 RE N 189041 Strain Relief st ee en ea ee Ge EE ee De ge ed 1 163 519 Cable Port 324 Rue p UE E ee 16 5 Ft IE EE 079 739 Conn circ coc clamp str rif 1 15 PLG12 141 162 Housing Plug Pins service kit 1 Mes PLG52 174 823 Housing Plug Pins Skts service kit 1 EE PLG74 115093 Housing Plug Skts service kit 1 16 RC40 140 047 637 Housing RcptrSkts service kit 2 KURR EES PLG34 134 136810 Housing Plug Skts service kit 2 cada PLG35 135 131 204 Housing Plug Skts service kit 2 SERE se PLG36 136 115 094 Housing Plug Skts service kit 2 dT EE EE ae 010494 Bushing Snap in Nyl 1 375 Id X 1 750 Mtg Hole 2 OM 1500 14 Page 36 Item Dia Part No Mkgs No Description Quantity Figure 10 2 Control Box Continued AE EED 134 201 Stand Off Support PC Card 312 375w Post amp lock 43 17 rests 204 721 Enclosure Control 1 REDE d
43. actory de faults indicated by WIPE in the upper dis play Resetting the unit will also turn off the password code feature OM 1500 14 Page 26 SECTION 6 SETTING SEQUENCE PARAMETERS Sequence Parameters In A Program I For more information on Sequence Push Button see Section 5 11 If time is set to zero in Weld sequence welding continues until Sequence Parameters gun trigger is released Volts IPM Seconds If time is set to zero in any timed sequence except Weld the sequence is skipped 1 Preflow 0 9 9 2 Run In X 3 Start X X 0 00 5 00 4 Weld X X 0 100 0 5 Crater X X 0 5 00 6 Burnback X 0 0 25 7 Postflow 0 9 9 X Setting available Weld Time er Crater Time m Burnback Time Start Preflow Time Postflow Time Time 1 5 Time gt Burnback Preflow Run In Start Weld Crater Postflow Sequence Trigger Trigger Pressed Released OM 1500 14 Page 27 SECTION 7 SETTING DUAL SCHEDULE PARAMETERS 7 1 Optional Dual Schedule Switch Diagrams 1 2 1 Dsse 1 x DSS8 4 TR 3 Bo gt A 3 1 Maint2P Maintained Contact 2 Pole Switch 2 Maint 1P Maintained Contact 1 Pole Switch EF Will not function with trigger hold and dual schedule A DSS 9 is recommended for this application
44. an explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder 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 com
45. arranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City 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 File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 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 5
46. as robots e Be sure all equipment in the welding area is electromagnetically compatible To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor 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 f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 1500 14 Page 3 1 4 California Proposition 65 Warnings A 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 A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins 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
47. ations 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 soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque 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
48. bustible 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 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 T 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 nn nn e d F FLYING SPARKS can cause injury y 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 flammables away N J e Puton grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards e MOVING PARTS can cause injury e Keep away from moving parts 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 t
49. 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 Shutoff shielding gas supply when not in use e Always ventilate confined spaces or use approved 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 c
50. d by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING 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 W
51. dard Speed Trend 12 M1 101 201231 Motor Gear 1 8hp 24vdc High Speed 0 1 rm 153491 Kit Brush Replacement consisting of 1 1 THIS MEE 153492 Cap Brush 2 2 a ROSA RUE Par S Ac MA 153 493 Brush Canon seduta ah a EE raa ARE xa OM 1500 14 Page 40 Item Dia Part No Mkgs No Description _ Quantity _ Model DS 12 DS 16 Figure 10 4 Drive Assembly Wire continued VEER ss Trete tot 184 136 Kit Brush 1 1 TA et es 155098 Kit Cover Motor Gearbox consisting of Tess T ea 153 550 Cover Motor Gearbox consisting of 1 1 RE GA a 155099 Gasket Cover 1 1 aua a rec EEN 155 100 ves ie Screw COVER ie acti ein GPA PR dam ra A X ag cd D aar OD 154031 Spacer Locating 2 2 mE RETE 133 493 Ring Rtng Ext 250 Shaft Grv X 025Thk 1 1 EE ER Ed 203 642 Pressure Arm R amp Vert L 4 Roll consisting of 1 1 ET N te 203 631 Pressure Arm S L amp Vert S R 4 Roll consisting of 1 1 Te 203 461 Washer Flat Indicator Spring Tension RE anu 18241
52. der 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 Manual Check gun trigger See gun Owner s Manual Readjust hub tension and drive roll pressure see Section 4 11 Change to correct size drive roll see Table 10 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 1
53. des organes mobiles tels que des ventilateurs e Maintenirferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N utiliser que les pi ces de rechange recom mand es par le constructeur Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F 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 qualif
54. 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 before 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 f
55. e For example if a trigger hold delay time of 2 0 seconds is defined and the operator held the trigger in for more than 6 0 seconds the trigger hold function would not be in effect and the wire feeder would stop when the trigger is released 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 operatorto 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 sequence Any combination of programs may be used Trigger Program Se lect 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 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
56. e ee ee ee ee ee ee ee hs 14 4 6 Control Box Connections 15 4 7 14 Pin Plug Information nanan aa ee RE ee ee RR RR hh rh nr 15 4 8 Removing Safety Collar And Adjusting Boom 16 4 9 Gun Recommendation Table 16 4 10 Wire Type Size And Feed Speed Capability Table 16 4 11 Installing And Threading Welding Wire 17 4 12 Setting Internal DIP Switches EE cece ee ee ee hs 18 4 13 Power Source Selection Menu 19 SECTION 5 OPERATION i ESE Re nd ses DEE GEE ne ee ees ree ee Sr Se theta ee 20 5 1 Operational Terms resta pb uh Roe ER Pare dac a OR Bed eran wR Ra 20 5 2 POWE Si tren den orne decem OR OE nd d da P EE 20 5 3 Left Right Select Switch erre err re ere een RS WE o TH es 20 5 4 Jog P rge Switch EER rere ge eere ab XU RU ERU EATER ees 21 5 5 Frorit Panel Controlee eibi e ia ave a eid hehe evoke SIR UEM RIXA EA a HE ER 21 5 6 Program Push Button ESE SEER PI EE SE DER eating Sh Neun LE Ses 22 5 7 Upper Display s Seve REB RUPEM ERIS be eg OE DS Ga Has a sadist s 22 5 8 Lower Display sets euo ee P REDE MEE EE IPIE be Lee ah ieee hber dE P 23 5 9
57. e 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 14 Page 9 OM 1500 14 Page 10 SECTION 3 INTRODUCTION 3 1 Specifications Type of Input Welding Power Wire Feed Speed Wire Diameter Welding Circuit Weight Power Source Type Range Range Rating 9 24 Volts AC PAST 106 mpm 0231018106 100 Volts sate m Single Phase pri i To 3 2 mm 750 Amperes 100 207 Ib 94 kg ith 14 Pin An Duty Cycle 10 Amperes Contactor Control Optional High Speed 92 Max Spool Weight di 16 ft 4 9 m 50 60 Hertz To 1435 ipm 60 Ib 27 kg 280 Ib 127 kg 2 3 To 36 5 mpm Maximum Height With 4 ft 1 2 m Post 12 ft 3 7 m Boom DS 12 16 ft 4 9 m Boom DS 16 17 ft 5 2 m 21 ft 6 4 m Vertical Lift Of Boom Horizontal to 60 Above Horizontal Horizontal to 60 Above Horizontal SECTION 4 INSTALLATION 4 1 Installing Swivel Into Pipe Post m A Do not remove Safety Collar d until instructed to 1 Swingpak Base or CBC Cart 2 Pipe Post With Base 3 Steel Bolt Secure as shown using as a mini mum 1 2 in diameter SAE grade 5 steel bolts
58. ecial instructions Pw 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 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 When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks 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 grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in
59. ecter 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 ger les 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 Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp 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 Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est util
60. eed 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 5 5 Front Panel Controls Volts Time sec See Section 5 7 See Section 9 Wire Speed 9 Amps 5 8 See Section Program 5 9 Start 9 Crater Pre Postflo Dual Schedule Trigger Hold e e Sequence Adjust Setup See See See Section Section Section 5 11 5 10 5 9 OM 1500 14 Page 21 5 6 Program Push Button Program 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 5 7 Upper Display To set the correct voltage range for a particular power source see Section 4 13 for power source selection menu or Section 5 12 for V Min And V Max adjustments 1 4 Volts 1 Upper Display Time sec 5 nates to indicate that information displayed can be changed by the Adjust control play push button
61. eing 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 5 2 Power Switch 1 Power Switch 803 193 5 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 E Engaging the Left or Right Gun Trigger also allows the operator to enable the con trols on that side of the unit 803 194 OM 1500 14 Page 20 5 4 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 activated after two minutes the jog operation is terminated to prevent com plete despooling of the wire in the case of a damaged gun e The unit displays the ERR TRIG message to inform the operator that the trigger is acti vated e Jog speed can be adjusted by the Adjust control when the unit is jogging wire The 1 Jog Purge Switch 2 Adjust Control 803 194 unit displays jog sp
62. fety Standards 2 4 1 6 Information SE ER EE TE RE ER OE OE EE 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Symboles S ru Ad orbs ne Pau GE Sees a me ne VER 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit 9 2 6 Information ER Se SO EE MR EE EDE Se DE ROSE RE RERO FRE Ra e E Ms 9 SECTION S INTRODUCTION mz ER ane Heed ee Er DoE Ee Dee ie dre nuire EE 11 3 1 Specificationso Es v eee RR RE RR Sa ER a M e S EDE doe eee nd Oa Arn gee s 11 SECTION 4 INSTALLATION 5e rx Rr Re ap ra gr a EE Ee GR irae eee pret 11 4 1 Installing Swivel Into Pipe Post ee EE Ee Re Ge ee ee ee ee ee ee eee s 11 4 2 Installing Control Box And Adjusting Tilt 12 4 3 Installing Boom And Reel Support 12 4 4 Installing Wire Guide Extension ie ee ee ee Ee ee ee ee teen ent s 13 4 5 Equipment Connection Diagram ii EE Re ee ee e
63. gram 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 e When the Sequence push button is pressed athird time the Preflow Postflow sequence LED flashes The Sequence push button LED remains flashing In the Preflow display mode the upper display shows the preflow time and the lower display indicates the ab breviation PRE to inform the operator that preflow time is displayed If the upper dis play push button is pressed the Adjust con trol can be used to adjust preflow If the lower display push button is pressed the Adjust control can be used to select between preflow PRE and 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
64. hreading welding wire AS STATIC ESD can damage PC boards x MOVING PARTS can cause injury NU 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 e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place 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 The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such
65. i 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 cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de ca 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 A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans cer
66. is 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 Ne pas installer l appareil proximit de pro duits inflammables Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser Vanneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil Enn L EMPLOI EXCESSIF peut SUR CHAUFFER L QUIPEMENT e Pr voir une p riode de refroidissement re specter le cycle op ratoire nominal River e R
67. isplayed Pushing the Setup push button will step through the menu Pushing the sequence push button will step through the menu in re verse gt The auxiliary menu may be exited at any time by pressing both the Sequence push button and the Setup push buttons simul taneously V Min And V Max e f the Setup push button is pressed the unit allows the setting of the manual override power source min and max voltage preset range The minimum voltage is displayed in the upper display and the lower display indi cates VMIN When the Setup push button is pressed the unit displays the maximum voltage setting of the welding power source The maximum voltage is displayed in the up per display and the lower display indicates VMAX In both cases the Adjust control is used to specify the minimum and maximum voltage settings of the welding power source The set tings correspond to arc voltage obtained at minimum command and arc voltage obtained at maximum command This method of setting VMIN and VMAX may be used if the power source being used is not listed in the Power Source Selection Menu 5 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 set tings E 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
68. lacement Parts Model and serial number required when ordering parts from your local distributor OM 1500 14 Page 39 F Hardware is common and not available unless listed See Table 10 1 For Drive Roll amp Wire Guide Kits 23 802 977 B Figure 10 4 Drive Assembly Wire Quantity Item Dia Part Model No Mkgs No Description DS 12 DS 16 Figure 10 4 Drive Assembly Wire Figure 10 1 Items 26 and 30 n ap amine 010 668 Screw Cap Stl Sch 250 20 X 1 500 4 4 DR re De EA 172 075 Carrier Drive Roll W Components 24 Pitch 4 4 PR RE E 149 962 Spacer Carrier Drive Roll 4 4 E sse Ang 149 486 Pin Rotation Arm Rocker 2 us 2 EE rete 163282 Nut 250 28 Stl 2i 165 798 Spring Pressure Arm Retaining 2 2 Den dur ere Oe is Jen 165 799 Washer Flat 257 Id Stl PR ne EE EO 132 750 4 Arm Pressure ist sata RED OD id wan 2 wu 2 ME ES 150 520 Spacer Rotation Pin giis EE erben 133 493 Ring Retaining Ext 250 Shaft X 025thk 2 eiie stas meme 139 350 PIn Hinge i eee en RE oe 12d 12 M1 101 201230 Motor Gear 1 8hp 24vdc Stan
69. lower display indicates BURN and the upper display indicates the burnback time or voltage The Adjust control is used to set the desired burnback time or voltage Burnback settings like run in settings are program spe cific The active program is displayed in the Program display and can be adjusted see Section 5 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 trig ger hold to work when the trigger is released the trigger hold function must be on For ex ample if a trigger hold delay time of 2 0 sec onds is defined the operator must hold the trigger for at least 2 seconds before releasing it in order for the trigger hold function to work Once the trigger hold function is in effect the wire feeder will stay On until the trigger is pressed and released again e There is an additional function built in called maximum trigger hold time which is the maximum length of time the trigger can be held and the trigger hold 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 trig ger hold delay tim
70. mode OM 1500 14 Page 24 5 12 Auxiliary Menus 2 Program Volts Time sec Wire Speed Start Crater Pre Postflow 3 1 Sequence Trigger Hold Dual Schedule Setup Amps N 6 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 ONOU BOND 5 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 con trol can be used to change the unit to WIPE ON When WIPE ON is set if the original four push buttons are simultaneously pressed a second time the unit will reset all settings to factory default except the arc time and arc cycle counts If a reset is not desired set the display to WIPE OFF and simultaneously press the Program Sequence upper display and Setup push buttons to exit the reset menu Auxiliary Menu e An auxiliary menu is provided if both the Se quence and Setup push buttons are pressed simultaneously The Setup push button and sequence push button LEDS flash when the auxiliary menu is d
71. mon and not available unless listed ST 081 760 C Figure 10 5 Support Hub amp Reel Item Part No No Description Quantity Figure 10 5 Support Hub and Reel Figure 10 1 Item 10 1 058 427 Ring Retaining Spool 2 2 136 684 Nut Stl SIflkg Hex Reg 625 11 W Nyl Insert 2 3 605941 Washer Flat Stl 640 Id X 1 000 Od X 14ga Thk 2 4 010 233 Spring Cprsn 970 Od X 120 Wire X 1 250 2 5 057971 Washer Flat Stl Keyed 1 500Dia X 125Thk 2 6 010191 Washer Fbr 656 Id X 1 500 Od X 425Thk 4 wk vas 058 628 3 Washer Brake Sil nee Aes ed da ENE oa ad ae REN sable dr 4 26 audi 058 428 Hub Spool de ES leu ESSO ARRA A tee as MEAM 2 219 080393 Support Reel ena Y Gente ge ee Sr ties ge 1 10 108 008 Reel Wire 60 Lb consisting of 2 1 124900 Support Reel Spool ioa nnn 1 12 168 104 Retainer Spool Support consisting of 1 EE Se at 166 594 Label Caution Falling Wire Reel Can Cause Damage 1 18 168 103 Nut Spanner Retaining
72. nly Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 1500 14 Page 35 Hardware is common and not available unless listed 803 200 Figure 10 2 Control Box Item Dia Part No Mkgs No Description Quantity Figure 10 2 Control Box Figure 10 1 Item 1 bo diae scatet 204722 Wrapper 1 Dre BES DS MUR ERES 134 464 Label Warning General Precautionary Static amp wire Fe 1 EE exe 206 764 Panel PC Card Front consisting 1 BE suet hance Ad 200 153 Overlay Front 1 4 PC21 200 693 Circuit Card Assy Switches 1 5 PC20 210683 Panel Pc Card Display W Program 1 nd ae 111 997 Switch Rocker Spst 10A 250vac On Off Visi Red Rock 1 7 POZO 220 903 Circuit Card Assy Dual W Program 1 8 PC1 101 217898 Circuit Card Assy Motor Control W Program 2 Pes alg ei wera we 030170 Bushing Snap in Nyl 750 Id X 1 000 Mtg Hole 1 S10 ER etna 000 527 Blank Snap in Nyl 875 Mtg Hole Black 1 TO es crt tes 047 838 Blank Snap in Nyl 1 000 Mtg Hole Bl
73. o not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit 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 DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone 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 Properly install and ground this equipment according to its Owner s Manual and national state and local codes EF Indicates sp
74. ocedure for opposite side Tools Needed CLEO ST 152 383 OM 1500 14 Page 13 4 5 Equipment Connection Diagram A ONOM 9 10 11 12 Welding Power Source Remote 14 Connection Negative Weld Output Cable Positive Weld Output Cable Workpiece Weld Control Boom Gun Swivel Pipe Post And Base Gas Hose Gas Supply and Regulator Customer Supplied Shielding gas pressure not to exceed 100 PSI 689 kPa 803 195 OM 1500 14 Page 14 4 6 Control Box Connections 1 Interconnecting Cables 2 Interconnecting Cable Receptacles 3 14 Cord 2 4 Lu B H 3 803 197 A 4 7 14 Pin Plug Information REMOTE Ji 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 OM 1500 14 Page 15 4 8 Removing Safety Collar And Adjusting Boom Tools
75. on 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 causera des champs lectromagn tiques Il 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 exposition 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
76. on and operation quick business and easy With Miller you can count on years 90 00012000 of reliable service with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in the U S A ta be registered to 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 Mill mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 124 Symbol Usage ii prb EER EDU Ue ether Ge PORNO Ee EP 1 1 2 Arc Welding Hazards ser it e REA ates iad cone habitat RA Da 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 2 4 1 5 Principal Sa
77. on which if 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 NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A A A Le 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 ELECTRIC SHOCK can kill n 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 D
78. 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 pipes 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 14 Page 2 L2 Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at
79. p Push Button LED 3 Trigger Hold LED 4 Dual Schedule LED e When the Setup button is pressed the Set up push button LED flashes and the Trigger Hold LED flashes e The flashing LED indicates that the unit is in the trigger hold display mode In this mode the upper display indicates HOLD and the lower display indicates the trigger hold sta tus On Off Use the Adjust control to change MNA 4 Trigger Hold Dual Schedule vie rd the trigger hold status 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 5 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 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 Setu
80. p 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 OM 1500 14 Page 23 5 10 Adjust Control 1 Adjust Control The Adjust control is used to change various sequence parame ters and to select various se quences Refer to the section for the function in question for informa tion related to using the Adjust con trol Adjust 5 11 Sequence Push Button 1 Sequence Push Button EE 2 Sequence Push Button LED 3 Start 3 Welding Sequence LEDs D crater Pre Postflow e1 2 Start hs Crater Time Time 1 fl L Postflow Sequence For more information on Setting Sequence Parameters see Section 6 1 The Sequence push button allows the selection of welding sequences Five weld ing sequences are available The default sequence is the Weld sequence The Weld sequence is active on power up Three welding sequence LEDs are located above the Sequence push button Start Crater and Preflow Postflow The applicable LED illuminates to indicate which welding se quence is active The LED illuminates to indicate that a weld ing sequence display mode other than Weld is activate Welding sequences other than Weld must be set prior to initiating the arc When the unit enters a welding state all se quence display modes are terminated and ap Time Welding Sequence Dia
81. place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object 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 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 OM 1500 14 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes 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 ai
82. r 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 shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards 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 Welding on closed containers such as tanks drums
83. s 3 9 1 Front Panel 2 Front Panel Board PC20 User Defined Shutdown Error Messages Additional hardware required for 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 NN 6 wg Refer to Section 5 12 for cor rect setup procedures 803 198 ERR ERR OPT1 OPT2 Indicates a User Defined Option Error SECTION 8 MAINTENANCE amp TROUBLESHOOTING 8 1 Routine Maintenance E t Z y A Disconnect power Maintain more often before maintaining during severe conditions 3 Months 7 WARNI Clean and Repair or 536 Replace tighten replace or Vy unreadable XE E weld Fi cracked labels terminals E y weld cable Replace Check Check gas Check gun cracked 14 pin cord hoseand parts fittings 6 Months Blow out or vacuum Clean inside During heavy drive rolls service clean monthly OM 1500 14 Page 30 8 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 4 5 and 4 6 Wire fee
84. s 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 gt Seul un personnel qualifi est autoris a installer faire fonc tionner entretenir et r parer cet appareil gt Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE DECHARGE ELECTRIQUE peut entrainer 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 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 mani re incorrecte ou impropre constitue un danger n Ne pas toucher aux pi ces lectriques sous tension e Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin
85. soline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A 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 Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 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
86. tains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants 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 14 Page 8 Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A 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 249 1 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 Associati
87. te 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 En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les cables doivent tre exempts d humidit 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
88. 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 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 14 Page 4 For Ga
89. wer 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 Wire Speed de 5 to indicate that information displayed can be changed by the Adjust control 4 Wire Speed LED 5 Amps LED The LEDs below the display illuminate to indi cate which value is being shown e If the unit is in a welding state that does not involve feeding wire the unit displays 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 just control is activated while welding the unit displays and permits adjustment of the weld sequence wire feed speed regardless of the active welding sequence When the unit is displaying amperage the Amps LED illuminates Amperage is only displayed if the unit is in a welding state and the amperage is above a minimum value of 25 Amps The display will read dashes for amperage readings below the amperage threshold prior to arc initiation 5 9 Setup Push Button 1 Setup Push Button Press button to choose between trigger hold or dual schedule functions 2 Setu
90. zzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE 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 Millers 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 determine

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