Home

Miller Electric 394F Welder User Manual

1. 1 EE 201 781 KNOB w extension clamp 1 EEN TC RE GEAMP motor el OS 1 le tance 145 639 STRIP buna N compressed sheet 062 x 4 000 x 4 000 1 jT 200 5527 za BASE vos cts caetero tet see et CR M I M M ede 1 Due use 134 306 FOOT rubber 1 250 dia x 1 875 high no 10 screw 4 20 1550 Sd aer nos 200557 STIFFENER base 1 Ale se Fig 9 2 CONTROL BOX 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 1500 1 Page 31 Hardware is common and not available unless listed 802 802 A Figure 10 2 Control Box Item Dia Par No Mkgs No Description Quantity Figure 10 2 Control Box Figure 10 1 Item 14 elo tei re eet 200555 WRAPPER feeder 1 SPP pete ne 200 153 OVERLAY upper front panel 1 CB ne dE au ae E 204 762 OVERLAY upper front panel CE Models 1 br idunt At 200 693 CIRCUIT CARD ASSY switches 1 Db codes oe e
2. 1 eed Dh Et i eos 604 772 WASHER flat stl SAE No 8 1 IO tle 182156 SPRING COST HEEN A OM 1500 1 Page 34 Item Dia Part No Mkgs No Description Quantity Figure 10 3 Drive Assembly Wire Figure 10 1 Item 23 contin ued APS MAS ous 182155 5 SPRING rreran eR ener PSU nt Moi en 2 TO Gom er 132746 BUSHING spring 2 19 5 bue 181522 5 SHAET Spring uso eme Eee Rte rato ete NEC 1 20 PE 132747 CARRIER shaft 1 El med 133 739 WASHER flat buna 375 ID x 625 OD x 062thk 1 RE exei iE 203 637 KNOB w extension long pressure arm 1 23 PC51 201225 CIRCUIT CARD digital tach consisting of 1 sabe does Od PLG5 181204 CONNECTOR amp SOCKETS EK EE 604 311 GROMMET rbr 250 ID x 375mtg hole 062 groove 1 WA eneTa tii 132611 OPTICAL ENCODER DISC 1 dunt RAE 603 115 WEATHER STRIPPING adh 125 x 375 1 P espe hel bate 167 3987 x SPACER locating ore bei pete ere rives D nine dl RE EE E 2 PO Fer 168 825 DRIVE PINION sera rate terre Xe ek Ek e NL KR ne kwa 1 Plate eU OH MEN 133308 RING retaining ext 375 shaft x 025thk 1 PO RM de 134 834 HO
3. Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks 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 Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance YA FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces
4. e Do notinstall unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas oylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit Re LU OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle a Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit ee STATIC ESD can damage PC boards 77 e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards O N MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire 5 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard 249 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U
5. HOUSING PLUG SKTS service kit d SEKR PLG6 36 115094 HOUSING PLUG SKTS service kit 1 p PLG37 38 047636 HOUSING PLUG PINS SKTS service kit d TTA RC13 080328 RCPTw SKTS free hanging d e Ne nee EE 203 423 BUSHING strain relief 300 360 ID x 689 sq mtg 1 seu oe EAS M ny 604 571 CABLE port no 18 4 c type sjo nprn jkt re 2ft OM 1500 1 Page 33 Hardware is common and not available unless listed See Table 9 1 For Drive Roll amp Wire Guide Kits 802 950 Figure 10 3 Drive Assembly Wire Item Dia Par No Mkgs No Description Quantity Figure 10 3 Drive Assembly Wire Figure 10 1 Item 23 ed WA EE 010 668 SCREW cap stl sch 250 20 x 1 500 4 EE 172075 CARRIER drive roll w components 4 aaa Oa men 149962 SPACER carrier drive roll 4 C 149486 PIN rotation arm rocker 2 VEE PERCHE 132750 ARM pressure 2 iD sinere 150520 SPACER flat stl 257 ID x 619 OD x 105 2 ur easet ss EL 133 493 RING retaining ext 250 shaft x 025thk 2 PC 133 350 BIN burger uere Centr
6. e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed
7. Locks On 10 and finally Locks On 20 If the wire speed is at 300 IPM when the lock DIP is activated and the lock range is set at 10 the operator would have an adjustment range from 270 to 330 IPM CS To changing Lock proceed as follows Turn power Off Place DIP switches S1 3 amp 4 in the Off position see 3 amp 4 above Turn power On and Off Place switches 3 amp 4 in desired new settings Turn power On and Off Trigger Hold and Dual Schedule function nor mally when locks are enabled Setting Display Hold Feature S1 5 If the display hold DIP is in the Hold On posi tion the unit will hold the last weld information for 5 seconds following weld termination If any front panel push button is pressed or if the Adjust control is activated the display hold feature is terminated Setting Current Detect Override S1 6 Current detect override is used to disable run in when a welding power source is used that doesn t provide current feedback through the 14 pin receptacle Defining Motor Speed S1 7 amp 8 Switches 7 and 8 allow the user to define whether the motor in use is normal speed 50 780 inches per minute or high speed 90 1440 inches per minute OM 1500 1 Page 15 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 Sequence Weld Program Cu
8. 201 549 CIRCUIT CARD ASSY motor control 1 T8 s Sie 111 997 SWITCH rocker spst 10A 250 VAC on off 1 FAO see rat excep 200 559 PANEL front site EE Meee KR e P tiens 1 OM 1500 1 Page 32 Item Dia Part No Mkgs No Description Quantity Figure 10 2 Control Box Figure 10 1 Item 14 Continued Ae S usse 92 125 200295 SWITCH rocker spdt 15A 12V on off on 1 vou esc erue as a ite 202 587 e NAMEPLATE preon Lieber lere nter vri Ee Tr meals ae Merk 1 EE 204 691 NAMEPLATE CE models 1 CETTE 179 851 KNOB pointer 1 670 dia x 250 id push on w spring 1 28 RC18 048 282 RCPT W SKTS service kit 1 Aid pu PLG6 115094 HOUSING PLUG SKTS service kit 1 Mul dM PLG11 61 131005 HOUSING PLUG SKTS service kit d m PLG1 202592 HOUSING PLUG PINS SKTS service kit 1 Tc PLG51 174 824 HOUSING PLUG PINS SKTS service kit 1 NEGLI PLG4 186810 HOUSING PLUG PINS SKTS service kit 1 che E PLG7 27 115091 HOUSING PLUG SKTS service kit 1 EET PLG10 130203 HOUSING PLUG SKTS service kit d plua rA ens 134
9. DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 7 00 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number
10. shows weld amperage during welding Off Front panel display shows wire feed speed during welding 1 234 56 7 8 Position Settings And Results For DIP Switch S1 On Front panel display shows wire feed speed in meters per minute Off Front panel display shows wire feed speed in inches per minute 3 4 3 Off 4 Off Range limit ing disabled locks Off 3 Off 4 On Range limit on voltage and wire feed speed set at 10 F In the DIP switch S1 illustrations the elevated slider on each switch is show in white For example the switches above are all in the Off position 802 808 3 On 4 Off Range limit on voltage and wire feed speed set at 5 3 On 4 On Range limit on voltage and wire feed speed set at 20 On Front panel display holds weld parameters for 5 seconds following trigger release Off Front panel display returns to preset upon trig ger release On Current detect overri de For welding power sources that don t provide current feedback through the 14 pin receptacle Off Current must be de tected to go from run in to welding condition 7
11. x ZE 8 MOIOSISS ZLI v09 M epino Jeewnuy EEZ SYO puy epino ejerpeuueju Spn 1eju uy Surejuo 1 uoe3 KI mois 106201 on ECS misi wm ue osezes EU ES ovis KI mois osszes EC EC seo 161 LE mois za EE 160 isi gzs 6r 166 0S1 ww g e LZS 6v4 966 OSL LZS 6v4 966 OSL OZS 6p S66 OSI OZS 6t S66 OSI Ul 270890 669 90 620 LSL OZS 6p S66 OSI 869 90 820 LSL eig 6p 6601 169 90 220 ISL eig 6t 6601 061 LOL 8lIS6rl 66 0S4 007 90 920 LSL 8IG 6p 66 0S4 896 ZEL 80 LSL 000 220 9 0 LSL low on G69 90 G20 LSL 66 0S L DCL 280 tzo LSL 8IG 6p 66 0S4 Ul G Ee t N S amp 1104 uoe Jang OHJOIN noed Sud Jald JAOOHI9 HA 3AOOH5 h JAOOU9 A SH 9PINO M PUY 10H SALI 71 6 9Iger 3AOOH9 0n OZIS JIM apin5 AJLIPOULIOJU OM 1500 1 Page 36 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way Miller The Power of Blue Effective January 1 2000 Equipment with a serial number preface of LA or newer This limited warranty supersedes all previous M
12. 0A A 1 50 60 Hz IP 21 CG U2 100V 1 750 A X 100 ST 178 794 A 2 3 Symbols And Definitions Note 5 Some symbols are found only on CE products A Amperes V Volts ENG Alternating Current X Duty Cycle P SE e H Z Hertz gt Program olo Wire Feed ojo Jog e Output Ca Trigger d i Line Connection lt gt Set Up Sequence gm Trigger Hold On la Trigger Hold Off e Purge Eo Press To Set Start Crater Time 5 Preflow Time 5 Postflow Time EN Read Instructions t D y y t2 b Increase 1 Primary Current L Rated Current U 2 Load Voltage A U 1 Primary Voltage gt Dual Schedule OM 1500 1 Page 10 SECTION 3 INTRODUCTION 3 1 Specifications e i Wire Welding Wier Welding Power ete diameter Codi pling wl wee Range Rating 24 Volts AC Constant Voltage CV Standard 50 To 023 To 1 8 in 100 Volts IP 21 Length 27 in 58 lb Single Phase DC With 14 Pin And 780 ipm 1 3 To 0 6 To 3 2 750 686 mm 26 kg 10 Amperes Contactor Control 19 8 mpm mm Amperes Ltb 49 4 0 50 60 Hertz 100 Duty irt SC n Optional High Max Spool Cycle f i Speed 90 To Weight 60 Ib Height 14 in 1440 ipm 2 3 To 27 kg 356 mm 36 6 mpm SECTION 4 INSTALLATION 4 1 Site Selection 1 Wire Feeder Pu 2 Rubber Feet Choose slot that allows all rubber feet to sit securely on top of welding power source
13. 3 Wire Spool Reel 4 Gas Oylinder w Hose And Re gualtor Customer Supplied Welding Power Source Running Gear Do not put feeder where welding wire hits cylinder D o Do not move or operate equipment when it could tip 7 Factory voltage settings are V Min 10 and V Max 38 If you are using a power source With a different voltage range see Section 5 10 for V Min And V Max adjustments Ref ST 152 468 A ST 152 467 C OM 1500 1 Page 11 4 2 Rear Panel Connections And Rotating Drive Assembly 1 14 Pin Control Cable 10 2 Shielding Gas Valve Fitting Requires fitting with 5 8 18 right hand threads Connect customer supplied gas hose 3 Weld Cable Terminal 4 Weld Cable 5 Drive Assembly 6 Drive Assembly Rotation Knob To rotate the drive assembly loos en drive assembly rotation knob rotate drive assembly and tighten knob Tools Needed 3 9g 16 5 8in 3 16 in 802 824 A 802 825 A OM 1500 1 Page 12 4 3 14 Pin Plug Information Lal REMOTE 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 de input from power source to wire feeder with respect to socket D D Re
14. 6 1 Sequence Parameters In A Program TPA Seguence Parameters Volts IPM Seconds 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 If time is set to zero in Weld Sequence welding continues until gun trigger is released If time is set to zero in any timed sequence except Weld the sequence is skipped Weld Time I gt Crater Time Fu Burnback Time Start Preflow NA Postilow Time Time ua Time gt Burnback Preflow Run In Start Weld Crater Postflow sequence Trigger Trigger Pressed Released OM 1500 1 Page 25 SECTION 7 SETTING DUAL SCHEDULE PARAMETERS 7 1 Optional Dual Schedule Switch Diagrams 1 Maint2P Maintained Contact 2 Pole Switch 2 2 Maint 1P Maintained Contact 1 Pole Switch 1 DSS 1 DSS 8 4 p EE ee 2 2 S TR No g 3 Bo SECTION 8 MAINTENANCE 8 1 Routine Maintenance GC 5 EX X ES A Disconnect power before maintaining 3 Months Q WARNIN Clean and Repair or OV SE S tigaten replace lt TS unreadable SEL weld Y cracked ios labels terminals zl 3 weld ee cable dl Replace SIA Check Check gas cracked Key 14 pin cord hoseand 4 B gun par
15. 646 LABEL Warning General Precautionary d EROR EE 178 936 LABEL Warning General Precautionary Wordless CE 1 Detach Option dita aite E 200562 WRAPPER control box 1 c 204 019 WRAPPER motor box 1 WEE 145 338 4 ANGLE FOO H EENEG DEG 604 311 GROMMET rbr 250ID x 375 mtg hole 4 EEN 000 527 BLANK snap in nyl 875 mtg hole black d t aie oad 192 465 BLANK snap in nyl 813 mtg hole black d ee are eer CET AT 070 371 BLANK snap in nyl 1 125 mtg hole black d E 024 376 BLANK snap in nyl 625 mtg hole black d 163 520 CABLE port no 18 14 11 c type AWM 2 14 9 18 CND CT 2bft rm 079 739 CONN circ cpc clamp str rif size 17 20 703 OD 2 TE PLG44 148389 HOUSING PLUG PINS SKTS service kit 1 eee ui PLG45 131 203 HOUSING PLUG PINS SKTS service kit 1 RS RC40 37 047637 HOUSING RECPT SKTS service kit d hod tu PLG46 115090 HOUSING PLUG PINS SKTS service kit 1 Msn PLG34 136810 HOUSING PLUG SKTS service kit 1 fog ege PLG35 131 204
16. LED 4 Dual Schedule LED When the Setup button is pressed the Set up push button LED illuminates and the Trig ger Hold LED flashes 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 2 gr m gt YL tus On Off Use the Adjust control to change the trigger hold status or press the lower dis play push button If trigger hold is turned On the trigger hold LED illuminates and stays On When trigger hold is On the user must press and hold the trigger for a predefined amount of time the trigger hold delay time see Section 5 10 then release it for the trig ger hold function to be active To shut off the weld when trigger hold is On the user must press and release the trigger f a weld time is programmed trigger hold is disabled CE Models When the Setup button is pressed a second time the dual schedule LED flashes In this mode the upper display indicates DUAL and the lower display indicates dual schedule status On Off Use the Adjust control to change the dual schedule status if desired Pressing the Setup button again exits the Setup mode The dual schedule LED stops flashing to indicate the dual schedule status is Off While in the Setup mode the active program can be adjusted without deactivating the trigger hold Setup mode operation If the trigger is
17. Off 8 Off Normal speed motor 50 780 inches per minute 7 Off 8 On High speed motor 90 1440 inches per minute 7 On 8 Off Reserved for future use 7 On 8 On Reserved for future use 1 DIP Switch S1 2 DIP Switch S4 Not For Customer Use DIP switch S1 allows the user to make a num ber of choices affecting unit operation Selecting Weld Amperage Or Wire Feed Speed Display S1 1 If the front panel DIP is set in the display amps position the lower display see Section 5 6 shows amperage while the unit is welding at an amperage value above 25 Amps and the current detect override is in the Off position If the amperage display position is not used the lower display shows wire speed Selecting Wire Feed Speed Value S1 2 The unit displays wire speed in units of inches per minute IPM if the English Metric wire feed display DIP is in the English position The unit displays wire speed in meters per minute MPM if the DIP is in the metric position Adjusting Range Limits S1 3 amp 4 The lock feature provides a means of regulat ing unit settings but still allows some level of adjustment through the Adjust control When a lock position is used the lock applies to all programs Two DIP switches are dedicated to locking unit settings Four possible combina tions of the two DIP switches provide the fol lowing settings Locks Off Locks On 595
18. Preset voltage is de fined as the desired arc voltage com manded to the welding power source e If the unit is displaying a welding sequence that can be timed the welding time display mode is entered by pressing the upper dis play push button repeatedly until welding time is the active parameter in the upper display At idle the upper display toggles between showing weld voltage or weld time with subsequent presses of the up per display push button The unit defaults to displaying welding voltage when a welding sequence display mode is first entered When the unit is ina welding state the welding time display mode is terminated in place of the voltage display mode If the weld sequence has a time set as in spot time after the weld program is com pleted ERR TRIG will be displayed to indi cate the weld program is complete Re lease trigger to clear error OM 1500 1 Page 18 5 6 Lower Display Lt l 0 Wire Speed Bul 5 1 Lower Display The lower display shows wire speed or amperage The unit displays and adjusts only preset wire speed at idle When the unit is in a welding state actual wire speed is dis played for the active welding sequence If the amps display DIP is set in the display amps position see Section 4 7 the lower display shows amperage while the unit is welding 2 Lower Display Push Button Press button to choose between wire speed or amperage func
19. RC27 PLG27 200 592 C it Diagram Ircul Figure 9 1 C OM 1500 1 Page 28 Notes OM 1500 1 Page 29 SECTION 10 PARTS LIST Hardware is common and not available unless listed nj 802 712 A Figure 10 1 Main Assembly OM 1500 1 Page 30 Item Part No No Description Quantity Figure 10 1 Main Assembly d e e ere 159647 INSULATOR motor clamp 1 osa totos M ede 159 646 CLAMP motor bas 2 iocos de rst nha RR Rex ERE Laara ee RR Ded 1 PTT OT 159 360 INSULATOR screw machine 4 duce Fig 9 3 DRIVE ASSEMBLY wire 1 D ener err 141 753 HUB 8 SPINDLE ASSEMBLY consisting of 1 Disco rd ars 058427 RING retaining spool 1 FR EU 180571 SHAFT support spool 1 NT 010233 SPRING cprsn 970 OD x 120 wire x 1 250pld 1 D aee ime abet 057 971 WASHER flat stl keyed 1 500dia x 125thk 1 ABEE 010 191 WASHER fbr 656 ID x 1 500 OD x 125thk 2 popped 058628 WASHER brake stl 2 EE 058428 e e TE Te EE 1 fire e siae Les 135205 NUT stl slflkg hex reg 625 11 w nylon insert 1 TA oe xxr 200556 SUPPORT spool
20. S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 O MOVING PARTS can cause injury e Keep away from moving parts such as fans CA e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as r
21. c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lec trocution et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES T peuvent blesser 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 vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 1500 1 Page 6 LES ACCUMULATIONS DE GAZ ris quent de provoquer des bless
22. containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding Eq FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 1500 1 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing
23. de soudage 5 d DES ORGANES MOBILES peuvent provoquer des blessures CA e Rester l cart des organes mobiles comme le ventilateur e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute frequence peut provoquer des interf rences avec les quipements de ra dio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appa reil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des Sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veille
24. 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 Arc Time e f the Setup push button is pressed the unit displays arc time in hours Arc time is indicated by the Program display showing HR Arc time is shown in the lower display Cycles e f the Setup push button is pressed the unit displays the number of cycles Arc cycles are indicated by the Program dis play showing CL The arc cycle count is shown in the lower display 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 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 o o Jo Om P ON 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
25. 5 gt gt a lt RC21 5 RC7 9 gt LI Jo lt RC27 9 RC7 10 25 BV COMMON 10 ete RC7 2 gt gt 25 70 e RC27 2 aen yy COMMAND 51 een aen sm COMMON 54 ee DETACHMENT OPTION OR WHEN USED AS SWINGARC RECEPTACLE LE Bo 8 e M N NI 4 22 RED 4 22 lt 9 pro BER 22 lt RCS 4 EEN Mai ie EN MEE FER a gt LWT ne 20 cis P BUS Al Ree 1 IYER ue eg P Saas Pt lt KEE M e e e Ti T PE JIS 2 5 lt M 5 gt lt Rc4 2 GS1 J6 J6 JE 1 A MR 4 gt lt lt RC4 1 9 PUR 9 WH d a e lt gt 6 gt lt RC4 4 17 11 EK se eue E Nu lt RO4 3 Ui ND wo M e ce 6 pus Ges pus ILE XE ev E 8 lt 3 lt 8 cae GER lt RC5 3 Wo 10 ST 19 c 2 Bene MY S 2 gt lt lt Res 2 O6 eo Bee M lt 1 lt 274 gt 7 mm lt R51 14 PIN D O e PLG12 zi zi za L1 S1 a CAN lt 1 Y ppp 2 No Aa c RCI G lt PURPLE lt 9 PEE SS y 2 AC COMMON lt lt RC1 1 B FED CONTACTOR lt lt RC3 5 F lt YELLOW CURRENT FEEDBACK RC3 1 H BROWN VOLTAGE FEEDBACK lt lt RC3 6 c lt PINK PS 10V lt lt RC3 2 E BLUE PS COMMAND lt lt RC3 4 D ORANGE PS COMMON lt lt RC3 3 amp WARNING Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit ELECTRIC SHOCK HAZARD USER SETTINGS FOR S4 PC20 INTERFACE BOARD RC21 PLG61
26. CE C Visit our website at www MillerWelds com Miller The Power of Blue OM 1500 1 200 510A May 2001 Processes MIG GMAW Welding Flux Cored FCAW Welding Gas And Self Shielded Description CV Lo Wire Feeder OWNER S MANUAL 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 n RU E BI H E that meets the high standards of quality and value established in 1929 R This Owner s Manual is designed to help you get the most out of your Working as hard as you do every power source from Miller products Please take time to read the Safety precautions They Miller is backed by the most will help you protect yourself against potential hazards on the worksite hassle free warranty in the business We ve made installation and operation quick and easy With Miller you can count on years of reliable servic
27. National Re search 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 con clusions 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 OM 1500 1 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos 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 c bles le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 DEFINITIONS 2 1 Warning Label Definitions A Warning Watch Out There ar
28. ODUCTION uses 11 E EE 11 SECTION INSTALLATION Aa Ix IA NIE EU eee at Be EVA x dre 11 4 1 Site Selection AE set erepto sue oU ER rtu A 11 4 2 Rear Panel Connections And Rotating Drive Assembly 12 4 3 14 Pin Plug Informations d ine Weg teen he Eeer Pu ETT honte E REI ee eee UE 13 4 4 Gun Recommendation Table 13 4 5 Wire Type Size And Feed Speed Capability Table 13 4 6 Installing And Threading Welding Wire 14 4 7 Setting Internal DIP Switches 15 SECTION 5 OPERATION lt ainina lxv nex IR E E EENS ET e A E Nie Se ENNER nee 16 5 1 Operational Terms ik c es dE EEN 16 5 2 Power Switch ina EN eerte Rer E RE te ed VE ENN PUE err v EE VH es 16 5 3 Front Panel Controls ee ccna Teteres tete aaa 17 5 4 Program PUSH Te ssa 2c ane net E gate pe nee ME E UEM els 18 5 5 Upper Display xe e ee Ra eee ee nde ecb ne ERR Re 18 5 6 Lower Display zones ccce REENEN 19 5 7 Setup Push Banton EE 19 5 8 Adjust Control wiss ane t vu RR ee ee v eee era 20 5 9 Sequence Push Button 20 5 10 A xlliary Mernus x oreet eer nee dada era E en de ee 22 5 11 Jog P rge 2er eme er ee aa neue RA ed Te CS a EA ER 24 SECTION 6 SETTING SEQ
29. Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Call 1 800 4 A Miller or see our website at www MillerWelds com to locate 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 sovice and Repair Miller Electric Mfg Co Replacement Parts An Illinois Tool Works Company 1635 West Spencer Street Training Schools Videos Books Appleton WI 54914 USA ae International Headquarters USA Technical Manuals Servicing Information USA Phone 920 735 4505 Auto Attended and Parts USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 Circuit Diag rams European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 Welding Process Handbooks www MillerWelds com Contact the Delivering Carrier for File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department Miller The Power of Blue PRINTED IN USA O 2001 Miller Electric Mfg Co 1 01
30. SE SAE 187 ID x 410 OD order by ft 2ft 29 5 Nb WERE ate 149 959 FITTING brs barbed M 3 16tbg x 312 24 1 SUL UE DN 179265 ADAPTER gun feeder 1 KEN mcd 108 940 SCREW cap stl hexhd 250 20 x 750 4 dot ee cora AE 604 538 WASHER flat stl SAE 312 1 cp 151437 KNOB piste T 1 125 lg x 312 18 x 1 500 1 i PT 151290 SCREW mach stl hexwhd 10 32 x 500 2 WA saben 179 277 COVER drive roll consisting of 1 PR DNE ERE 178 937 LABEL warning electric shock d BG s rie 601 872 NUT stl hex full fnsh 375 16 1 TAONA WEEK 602213 WASHER lock stl split 375 1 BB Sle Ree 602 243 WASHER flat stl std 375 1 BO ake boe Ri 601 966 SCREW cap stl hexhd 375 16 x 1 250 1 Optional High Speed Motor 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 1 Page 35 O LES0 S Jeu SIIOH SAUA v UUM Buoje GZL
31. UENCE PARAMETERS 25 6 1 Sequence Parameters In A Program 25 SECTION 7 SETTING DUAL SCHEDULE PARAMETERS 26 7 1 Optional Dual Schedule Switch Diagrams 26 SECTION G MAINTENANGE eek 3 RR ERI MEE NERRR ERE NUR ent sec ste eee 26 8 1 Routine Maintenance 444 heh eh hh hh e hh 26 8 27 DiagnOStiGS see eue ss at ee sn epa RaPert e oder EP 27 SECTION 9 ELECTRICAL DIAGRAM n nnn 28 SECTION 10 PARTS LIST 12 EN 43g gane re xe Ye x man ee a at ae a ay 30 Warranty Declaration of Conformity for European Community CE Products Note L3 This information is provided for units with CE certification see rating label on unit Manufacturer s Name Miller Electric Mfg Co Manufacturer s Address 1635 W Spencer Street Appleton WI 54914 USA Declares that the product T1 4 D conforms to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC Electromagnetic Compatibility EMC Directive 89 336 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Arc Welding Equipment Part I Welding Power Sources IEC 60974 1 September 1998 Second Edition Arc Welding Equipment Wirefeed Systems IEC 974 5 September 1997 Draft Revision Degrees of Protection Provided By Enclosures IP Cod
32. activated Setup mode s is termi nated OM 1500 1 Page 19 5 8 Adjust Control Ll 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 Non CE Models CE Models 5 9 Sequence Push Button 1 Sequence Push Button TEN 2 Sequence Push Button LED Start eJ 3 Welding Sequence LEDs 3 x 3 9 Crater hl e Sk Pre Postflow e t t2 Weld ar 2 2 Start eg Crater e rH Time Time 1 L cT FL we Poston UN ja Time p 1 Sequence Welding Sequence Diagram Non CE Models CE Models 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 and is indi cated when no welding sequence LEDs are illuminated Three welding sequence LEDs are located above the Sequence push but ton Start Crater and Preflow Postflow The applicable LED illuminates to indicate which welding sequence 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 the weld display
33. al Error Messages Additional hardware required for these to be functional Gas flow error indicates no gas flow is de tected Connect a gas supply or remedy the problems not allowing gas to flow Coolant flow error indicates no coolant flow is detected Connect a coolant system or reme dy the problems not allowing coolant to flow OM 1500 1 Page 27 SECTION 9 ELECTRICAL DIAGRAM PC1 MOTOR BOARD RC1 PLG1 RC3 PLG3 RC4 PLG4 RC5 PLG5 RC6 PLG6 RC7 PLG7 RC10 PLG10 RC11 PLG11 JOG 12 RC10 5 SE SC I O s2 RC10 4 EE 2 FS1 OPTIONAL COOLANT FLOW OUTPUT 122 RC26 SE GAS FLOW SWITCH GAS FLOW OUTPUT GAS FLOW INPUT COOLANT FLOW INPUT 2 gt gt RC24 2 gt RC26 RC24 1 gt NOTE FOR FEE DIP_SWITCH SE TINGS DERS WITH A STANDARD SPEED MOTOR THE FACTORY DEFAULT SETTINGS FOR S1 amp S4 ARE OFF DIP SWITCH SETTINGS FOR S1 POSN 1 ON DISPLAY WELD AMPS POSN 2 ON WFS IN METERS POSN 3 ON RANGE LIMITS POSN 4 ON RANGE LIMITS POSN 5 ON HOLD DISPLAY 5 SEC POSN 6 ON DISABLE RUN IN CURRENT DETECT POSN 7 ALWAYS IN OFF POSITION POSN 8 ON HIGH SPEED MOTOR DIP SWITCH SETTINGS FOR S4 THERE ARE NO RC11 1 gt De 17 lt RC21 1 RC11 2 gt HERO 4 lt RC21 2 4 35V COMMON RC11
34. ans un espace ferm seulement S il est bien ventil ou en ee i GER portant un respirateur alimentation d air Demander toujours un e Toujours v rifier la terre du cordon d alimentation V rifier et s assu surveillant d ment form de se tenir proximit Des fum es et des rer que le fil de terre du cordon d alimentation est bien raccord la gaz de soudage peuvent d placer l air et abaisser le niveau d oxy borne de terre du sectionneur ou que la fiche du cordon est raccord e g ne provoquant des blessures ou des accidents mortels S assu une prise correctement mise la feng ie rer que l air de respiration ne pr sente aucun danger e En effectuant les raccordements d entr e fixer d abord le conducteur e Ne pas souder dans des endroits situ s proximit d op rations de de mise ala terre appropri et contre v rifier les connexions d graissage de nettoyage ou de pulv risation La chaleur et les e V rifier fr quemment le cordon d alimentation pour voir s il n est pas rayons de l arc peuvent r agir en pr sence de vapeurs et former des endommag ou d nud remplacer le cordon imm diatement s il est gaz hautement toxiques et irritants endommag un c ble d nud peut provoquer une lectrocution e Ne pas souder des m taux munis d un rev tement tels que l acier e Mettre l appareil hors tension quand on ne l utilise pas galvanis plaqu en plomb ou au cadmium moins que le rev te e Ne pas utili
35. ch 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 1 Page 4 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION AEN Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de conna tre les mesures prendre pour vi
36. 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 som nd 4 98 e A i This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e lf earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can b
37. ctifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate 185 amp Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HFUnits Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment 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 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 Canvas Covers Millers True Blue amp Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Miller but manufactured by others suc
38. display to WIPE OFF and simultaneously press the Program Sequence upper display and Setup push buttons to exit the reset menu OM 1500 1 Page 23 5 11 Jog Purge 1 Jog Purge Push Button 2 Adjust Control 3 Gun Trigger Receptacle 802 807 1 Pressing the Jog Purge switch allows the op jog operation is terminated to prevent com control when the unit is jogging wire The erator to jog wire without energizing the weld plete despooling of the wire in the case of unit displays jog speed when the unit is be power or gas valve circuit a damaged gun This function is not avail ing jogged e The unit provides the ability to jog the wire able if current detect override is enabled do canaio be accomplished b f DIP switch S1 6 is in On position gging p y eeder by means of the gun trigger or the pressing the Jog Purge button Jog Purge switch If the welding arc does The unit displays the ERR TRIG message not initiate in 3 seconds after the gun trigger to inform the operator that the trigger is acti Pressing the Jog Purge button also allows is activated the unit will perform a jog opera vated the operator to purge gas lines before weld tion for a maximum of two minutes If the gun ing and to preset gas pressure at the trigger is still activated after two minutes the e Jog speed can be adjusted by the Adjust regulator OM 1500 1 Page 24 SECTION 6 SETTING SEQUENCE PARAMETERS
39. e IEC 529 November 1989 First Edition Insulation Coordination For Equipment With Low Voltage Systems Part I Principles Requirements and Tests IEC 664 1 October 1992 First Edition Electromagnetic Compatibility EMC EN 50199 August 1995 European Contact Mr Danilo Fedolfi Managing Director MILLER Europe S r l Via Privata Iseo 20098 San Giuliano Milanese Italy Telephone 39 02 98290 1 Fax 39 02 98281 552 dec con 11 96 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage A Marks a special safety message Means Warning Watch Out There are possible hazards With this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 4 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away IE 5 ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrical
40. e 200 691 PANEL pc card display micro 1 RD oor het it eerte 200 551 zi ENCLOSURE ontrol ic trs sits ae nime vex REY SA gees Ex 1 DS Or diat iei totes DI ets 134201 STAND OFF SUPPORT pc card 6 c UN WI EE 200 554 ENCLOSURE motor 1 T ieee ens 010 494 BUSHING snap in nyl 1 375 id x 1 750 mtg hole 1 OO eed sae ie Ba 057 357 BUSHING snap in nyl 937 id x 1 125 mtg hole 1 denas a etes Tant mn ca 200 196 CABLE power consisting of d 1102s resins 163 519 2122 CABLE POM ii eie eret bre e eh breeders e predios 11 5 ft ay h preted a beets te Mate 189 041 SS TRAIN RELIEF 2 bre Pannes Marennes pote teed 1 nns le SE Ee 079 739 CONN circ cpc clamp str rif 1 18 PLG12 141162 HOUSING PLUG PINS service kit 1 Mens PLG52 174823 HOUSING PLUG PINS SKTS service kit 1 EN PLG3 115093 HOUSING PLUG SKTS service kit 1 SA siste secures 605 227 NUT 750 14 knurled1 68dia 41h nyl 1 et o es 200 333 VALVE 34 VDC 2 way custom port 1 8 orf 1 at EEN Diy than 203 197 wa INDUCTOR Input reborn yir Ren mer ati rm ties ee 1 17 PCL ass
41. e Sequence push button is pressed a fourth time all sequence LEDs and the Sequence push button LED go off and the unit returns to the welding sequence display mode OM 1500 1 Page 20 Notes OM 1500 1 Page 21 5 10 Auxiliary Menus 7 Non CE Models A Program Volts Time sec ra Wire Speed Amps N Start Crater Pre Postflow Trigger Hold Dual Schedule BRUN P i Lo 8 CE Models 4 5 LT 7 e do eA 6 A SEN o e We ws 9 9 e e A x k OM 1500 1 Page 22 Auxiliary Menu An auxiliary menu is provided if both the Se quence and Setup push buttons are pressed simultaneously The Setup push button LED flashes when the auxiliary menu is displayed EF The auxiliary menu may be exited at any time by pressing both the Sequence push button and the Setup push buttons simul taneously Run In The Setup push button is used to step through menu selections The Manual over ride run in wire speed selection is indicated by the upper display of RUNI and the low er display indicates the run in wire speed setting of the active program The Adjust control is used to set the desired run in wire speed The lower display shows AUTO to indicate that automatic run in is active The Adjust con trol can be used to change the setting from AUTO to a
42. e 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 exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 1500 1 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld
43. e possible hazards as shown by the symbols B Drive rolls can injure fingers C Welding wire and drive parts are at welding voltage during operation keep hands and metal objects clear 1 Electric shock can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Don t weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watch person ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label OM 1500 1 Page 9 2 2 Rating Label For CE Products For label location see Section 4 2 DE U 24 VN 4 10
44. e rS DE n merce o hme ed 1 Lue dese MA Seis 201230 MOTOR gear 1 8hp 24VDC standard speed 1 9 M1 201231 MOTOR gear 1 8hp 24VDC high speed 1 d ates ict A cook uid S te 153 491 KIT brush replacement consisting of d ur 153 492 GAB BRUSH S c irure eh eg ete ee Por tte ut de EE do re 153493 BRUSH carbon 2 Que xen dci a i sede taber 184 136 KIT brush holder replacement d AES e comte 155098 KIT cover motor gearbox consisting of 1 153550 COVER motor gearbox consisting of d Leu e Nep EE 155 099 GASKET cover 1 EE 155 100 2 SCREW COVer ut e Vu ee EE EES in ea ae SH GD NAN RIS Cut 154031 SPACER locating 2 EE 133 493 RING rtng ext 250 shaft grv x 025thk d PERO 173837 PRESSURE ARM consisting of 1 ER NM ORE 182414 WASHER flat 2 1 au Testo Laurie 182415 PIN Cotter Dali san ses dre eimanse init rue ni DERI 1 b GE 203 640 KNOB w extension short pressure arm 1 BK DEEN 602 200 WASHER lock stl split No 8
45. e with proper maintenance And if for some reason the unit needs repair REGISTERED QUALITY SYSTEM there s a Troubleshooting section that will Miller is the first welding help you figure out what the problem is The equipment manufacturer in ins LS A to be registered fo parts list will then help you to decide which the ISO 9001 Quality System exact part you may need to fix the problem Au Warranty and service information for your particular model are also provided Miller offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local distributor Your distributor can also supply you with Welding Process Manuals such as SMAW GTAW GMAW and GMAW P Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Miller The Power of Blue amp WARNING This product when used for welding or cutting 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 The following te
46. 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 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 time For example if a trigger hold delay time of 2 0 seconds is defined and the operator held the trigger in for more than 6 0 seconds the trigger hold function would not be in effect and the wire feeder would stop when the trigger is released When the Setup push button is pressed again the menu repeats to the first menu selection of run in wire speed selection 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 and the lower display prompts the operator with the word ON or OFF The lower push but ton is active indicating that the Adjust control 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
47. h as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR
48. ice LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil les de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour Soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil nn jt i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT a e Pr voir une p riode de refroidissement respec v ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage Ne pas obstruer les passages d air du poste ee LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s 79 amp e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres person nes ou toute pi ce m canique en engageant le fil
49. iller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Re
50. la pi ce ou la terre etre dangereux e Ne pas se servir de source lectrique courant lectrique dans les zones Le soudage g n re des fum es et des gaz Leur humides dans les endroits confin s ou l o on risque de tomber inhalation peut tre dangereux pour votre sant e Se servir d une source lectrique acourant lectrique UNIQUEMENT si le e Eloigner votre t te des fum es Ne pas respirer proc d de soudage le demande les fum es e Sil utilisation d une source lectrique acourant lectrique s av re n ces e A l int rieur ventiler la zone et ou utiliser un chappement au niveau saire se servir de la fonction de t l commande si l appareil en est quip de l arc pour l vacuation des fum es et des gaz de soudage e Couper l alimentation ou arr ter le moteur avant de proc der l instal e Sila ventilation est insuffisante utiliser un respirateur alimenta lation la r paration ou l entretien de l appareil D verrouiller tion d air homologu l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de Se ET xe s curit e Lire les sp cifications de s curit des mat riaux MSDSs et les R instructions du fabricant concernant les m taux les consomma e Installer et mettre la terre correctement cet appareil conform ment bles les rev tements les nettoyants et les d graisseurs son manuel d utilisation et aux codes nationaux provinciaux et i n x municipaux e Travailler d
51. lect 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 5 Upper Display 7 Factory voltage settings are V Min 10 and V Max 38 If you are using a power source with a different vollage range see Section 5 10 for V Min And V Max adjustments Non CE Models LET E Volts 1 ins e i peu Time sec OX 5 CE Models gt o 3 ua V B 5 1 Upper Display 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 the Time LED is illuminated 2 Upper Display Push Button Press button to choose between voltage or time functions 3 Upper Display Push Button LED The upper display push button LED illumi nates to indicate that information displayed can be changed by the Adjust control 4 Volts LED 5 Time LED The LEDs below the display illuminate to in dicate which value is being shown At any time while welding the unit permits the adjustment of the weld sequence voltage and overrides the display of actual arc volt age e f the current detect override is in the On position see Section 4 7 the unit dis plays preset voltage while welding instead of actual arc voltage
52. lip AE 1 NONCONDUCTIVE E ON SURFACE x Drive Rolls yon Cable o E End Of Liner EF Be sure that outlet cable has proper size liner for the welding wire size When installing gun position liner extending from outlet wire guide as close as possible to drive rolls without touching Install gun Lay gun cable out straight Cut off end of wire Push wire through guides up to drive rolls continue to hold wire Press Jog button to feed wire out gun EF For soft wire or small diameter stainless steel wire reduce drive roll pressure on the rear roll to half that of the front rolls Tools Needed Se 3 16 5 64 in E Bn x 15 16 3 8 in To adjust drive roll pressure hold nozzle about 2 in 51 mm from nonconductive surface and press gun trigger to feed wire against surface Tighten knob so wire does not slip Do not overtighten If con tact tip is completely blocked wire should slip at the feeder see pressure adjust ment above Cut wire off Close cover Ref 156 929 A Ref 150 922 Ref 156 930 802 954 S 0627 A OM 1500 1 Page 14 4 7 Setting Internal DIP Switches 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 On Front panel display
53. ly live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or Servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power
54. 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 and all other sequence LEDs are Off When the Se quence push button is pressed the Se quence push button and the Start LEDs illu minate 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 Start sequence LED goes Off and the Crater sequence LED illu minates The Sequence push button LED remains illuminated In this condition the unit is in the Crater sequence display mode and Crater sequence parameters are shown in the displays When the Sequence push button is pressed athird time the Crater sequence LED goes Off and the Preflow Postflow sequence LED illuminates The Sequence push but ton LED remains illuminated In the Preflow display mode the upper display shows the preflow time and the lower display indicates the abbreviation PRE to inform the operator that preflow time is displayed If the upper display push button is pressed the Adjust control 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 When th
55. mote 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 4 4 Gun Recommendation Table Process Gun GMAW Hard or Cored Wires Roughneck C Series Guns 300 400 500 And 600 Amp FCAW Self Shielding Wires FC 1260 Or FC 1150 4 5 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 ea All 023 To 5 64 in 0 6 To 2 mm 90 To 1440 ipm 2 3 To 36 6 mpm OM 1500 1 Page 13 4 6 Installing And Threading Welding Wire Install wire spool Adjust tension nut so wire is taut when wire feed stops Install wire guides and anti wear guide Install drive rolls Wire Slips NONCONDUCTIVE SURFACE DI Pressure 1 Indicator f Pressure Scale Adjust Bo N Pressure Si ons Adjust NN Front Ly Rolls SG No Wire S
56. n for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage 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 ex amin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du
57. n support stationnai re ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits 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 Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance S Risque D INCENDIE OU f D EXPLOSION e Ne pas placer l appareil sur au dessus ou proxi mit de surfaces infllammables Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn et prot g avant de mettre l appareil en serv
58. obots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec 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 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 OM 1500 1 Page 3 1 5 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 su
59. one if a motor error and a communica tion error existed the light would blink four times for the motor error Since blink On time and blink Off time are equal in a four blink cycle the four blink se quence appears as a constant blink Indicates a motor error Indicates a tachometer error 1 blink Communication Error 2 blinks Trigger Error 3 blinks Tach Error 4 blinks Motor Error e The communication error occurs 2 5 sec onds after a loss of communication between the motor and front panel boards The user may continue to weld with this error The er ror may be cleared by resetting the unit see Section 5 10 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 No coolant flow detected No gas flow detected The tach error occurs 2 seconds after the loss of tachometer feedback The user may continue to weld with this error The motor speedis regulated through the monitoring of voltage and current The motor error indicates that the motor has been drawing too much current for too long To remedy this reduce the wire feed speed or the wire feeder torque load duty cycle Addition
60. r ce que tout l quipement de la zone de soudage soit com patible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipement lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e Encasd iterf rences apr s avoir pris les mesures pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l uti lisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 1500 1 Page 7 1 4 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Wel ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparatio
61. rms are used interchangeably throughout this manual TIG GTAW Stick SMAW OM 1500 1 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 Symbol Usage is crea sb kini aaa Wawa d fad tir x gu Aa 1 1 2 Arc Welding Hazards ss cene ree PYAR ek a ee RR Ren Era et 1 1 8 Additional Symbols For Installation Operation And Maintenance 3 1 4 Principal Safety Standards 3 1 5 EME Informatior AA AAA thue ev WAKAKA Un er let 4 SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 5 1 1 Signification des symboles 5 1 2 Dangers relatifs au soudage l arc 5 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement otla maintenance sister m rae rem ket Yd vie Ces aa f Ce I E E E Et 7 1 4 Principales normes de s curit 8 1 5 Information sur les champs lectromagn tiques 8 SECTION 2 DEFINITIONS 9 2 1 Warning Label Definitions 5 eret ne er manettes NUES NEAN ERN E date 9 2 2 Rating Label For CE Products 10 2 3 Symbols And Definitions 10 SECTION 3 INTR
62. rrent Detect Override Feeding wire without contactor or gas valve being energized A portion of the weld program such as preflow run in start weld crater burnback and postflow A group of sequences that make up a weld cycle Is used to disable run in when a welding power source is used that doesn t provide current feedback through the 14 pin receptacle 5 2 Power Switch 1 Power Switch 802 809 A OM 1500 1 Page 16 5 3 Front Panel Controls Nameplate For Non CE Models See Section 5 5 See Section Program Volts 6 Time sec See zi Section 5 6 Wire Speed Amps Start Crater Dual Schedule e Pre Postflo Trigger Hold a e e Sequence Adjust Setup 7 T 7 See See See Section Section Section 5 9 5 8 5 7 Nameplate For CE Models See Section See 5 5 Section e gt ev et See Section Ki e olo eA eZ e e E Oo hh hf e a t t2 3 e SETUP WA WA See Section Section Section 5 9 5 8 5 7 OM 1500 1 Page 17 5 4 Program Push Button Non CE Models een Program CE Models 1 Program Display The number of the active program is displayed 2 Program Push Button Press button to activate program se
63. run in wire speed setting 50 780 The active program is displayed in the Program display The active program can be changed by pressing the Program push button then selecting the desired program with the Adjust control Run in settings are program specific For ex ample program 1 can be set at 50 IPM run in and program 2 can remain on the Automatic setting When the unit is set for Automatic run in wire speed is set automatically to one half weld sequence wire speed Burnback e f the Setup push button is pressed the unit allows burnback time to be set Burnback time and voltage can be specified when the lower display indicates BURN and the upper display indicates the burnback time or voltage The Adjust control is used to set the desired burnback time or voltage Burnback Settings like run in settings are program spe cific The active program is displayed in the Program display and can be adjusted see Section 5 4 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 upper display and the lower display indi cates VMAX In both cases the Adjust control is used
64. s enfants UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous avec la pi ce souder ou la table de travail le plus pr s possible de la soudure Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il ya DU COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimenta tion lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie entretien avant de toucher les pi ces tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne comportant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres LES FUM ES ET LES GAZ peuvent moyens isolants suffisamment grands pour emp cher le contact phy tre d sique ventuel avec
65. ser des c bles us s endommag s de grosseur insuffi ment n ait t enlev dans la zone de soudure que l endroit soit bien sante ou mal piss s ventil et si n cessaire en portant un respirateur alimentation e Ne pas enrouler les c bles autour du corps d air d aH tous GR m taux Sue M l ments e Sila pi ce soud e doit tre mise la terre le faire directement avec un peuvenudegager des TumEees toxiques cn eas eg soudage c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine OM 1500 1 Page 5 LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas re garder l arc e Porter des v tements de protec
66. ter tout danger som nd fre 4 98 1 1 A identifie un message de s curit particulier Signification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc A Les symboles pr sent s ci apr s sont utilis s tout au long du e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le pr sent manuel pour attirer votre attention et identifier les risques champ les pi ces endommag es Entretenir l appareil conform ment de danger Lorsque vous voyez un symbole soyez vigilant et ce manuel suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font que r sumer e Porter un harnais de s curit quand on travaille en hauteur l information contenue dans les normes de s curit num r es 1 a la section 1 4 Veuillez lire et respecter toutes ces normes de Maintenir solidement en place tous les panneaux et capots s curit e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal EE L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus par ticulierement le
67. tion constitu dans une mati re dura ble r sistant au feu cuir ou laine et une protection des pieds F LE SOUDAGE peut provoquer un TER incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincel les des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre
68. tions 3 Lower Display Push Button LED The lower display push button LED illumi e olo nates 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 in dicate which value is being shown e f the unit is in a welding state that does not involve feeding wire the unit displays the weld sequence wire speed At any time during welding the weld sequence wire speed can be adjusted and overrides the preset wire speed display In other words if the Adjust control is activated while weld ing the unit displays and permits adjust sl Ley 3 Non CE Models 3 2 CE Models ment of the weld sequence wire feed speed regardless of the active welding se quence 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 zero for amperage readings below the amperage threshold prior to arc initiation In addition the am perage display feature is disabled if the current detect override is in the On position see Section 4 7 5 7 Setup Push Button 1 Te Trigger Hold Dual Schedule EA Setup Non CE Models Setup Push Button Press button to choose between trigger hold or dual schedule functions 2 Setup Push Button LED 3 Trigger Hold
69. ts e fittings 6 Months d Clean D i de drive rolls OK Jis Blow out or vacuum inside During heavy Service clean monthly OM 1500 1 Page 26 8 2 Diagnostics would be in place The following error messages are shown on the upper and lower displays to indicate specific errors Explanations are in the text below e a AUNI Wrapper Motor Control Board PC1 LED3 DIP Switch S1 EF There is a two position DIP switch S1 located on motor control board PC1 These switches are factory set in the off position and must remain in that position for the unit to operate correctly Front panel is shown removed for purpose of illustration only In actual use front panel Ref 802 687 ERR ERR ERR ERR ERR ERR COMM TRIG TACH MTR GAS COOL Indicates a Indicates a trigger communication error error LED3 Related Error Indications Error conditions are indicated by LED3 on PC1 To view LED3 turn Off unit remove wrapper and turn unit On LED3 is most easily observed from the left side of the unit The LED blinks in a 2 5 second cycle The number of blinks in this period indicates the type of error The priority of the errors is related to the num ber of blinks indicating the error The more blinks the more severe the error motor error is top priority A higher priority error overrides a lower
70. ures 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 confin s ou se servir d un respi rateur d adduction d air homologu DES PI CES CHAUDES peuvent pro voquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tin celles et des arcs e Placer les bouteilles debout en les fixant dans u

Miller Electric 394F Welder User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents