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Miller Electric OM-1500-4 manual

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Table of contents for the manual

  • Page 1

    Visit our website at www.MillerWelds.com 714S Processes Description MIG (GMA W) W elding Flux Cored (FCA W) W elding (Gas- And Self-Shielded) Wire Feeder OM-1500-4 203 211 June 2001[...]

  • Page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • Page 3

    The following terms are used interchangeably throughout this manual: TIG = GT AW Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-1500-4 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! W at[...]

  • Page 6

    OM-1500-4 Page 2 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. ARC RA YS can burn eyes and skin. D 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 [...]

  • Page 7

    OM-1500-4 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. [...]

  • Page 8

    OM-1500-4 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding 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 year[...]

  • Page 9

    OM-1500-4 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulier[...]

  • Page 10

    OM-1500-4 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dans[...]

  • Page 11

    OM-1500-4 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharge[...]

  • Page 12

    OM-1500-4 Page 8 1-4. Principales normes de s é curit é Safety in W elding 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 Of fice, Washington, D.C. 20402. Recommended Safe Practice for t[...]

  • Page 13

    OM-1500-4 Page 9 SECTION 2 – INTRODUCTION 2-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating IP Rating Overall Dimensions W eight 24 V olts AC Single-Phase 10 Amperes 50/60 Hertz Constant V oltage (CV) DC With 14-Pin And Contactor Control Standard: 50 T o 780 ipm [...]

  • Page 14

    OM-1500-4 Page 10 SECTION 3 – INST ALLA TION 802 806-A 1 Wire Feeder 2 Rubber Feet Choose slot that allows all rubber feet t o sit securely on top of welding power source. 3 Wire Spool/Reel 4 Gas Cylinder w/Hose And Re- gualtor (Customer Supplied) 5 W elding Power Source 6 Running Gear Y Do not put feeder where welding wire hits cylinder . Y Do n[...]

  • Page 15

    OM-1500-4 Page 1 1 3-2. Rear Panel Connections And Rotating Drive Assembly 802 824-A / 802 825-A 2 3 4 1 14-Pin Control Cable - 10 ’ 2 Shielding Gas V alve Fitting Requires fitting with 5/8-18 right- hand threads. Connect customer- supplied gas hose. 3 Weld Cable T erminal 4 Weld Cable 5 Drive Assembly 6 Drive Assembly Rotation Knob T o rotate th[...]

  • Page 16

    OM-1500-4 Page 12 3-3. 14-Pin Plug Information Pin* Pin Information A 24 volts ac with respect to socket G. A J B Contact closure to A completes 24 volts ac contactor control circuit. A J B K I G Circuit common for 24 volts AC circuit. C L N H C +10 volts dc input from power source to wire feeder with respect to socket D. D M G E F D Remote control[...]

  • Page 17

    OM-1500-4 Page 13 3-6. Installing And Threading Welding Wire Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / S-0627-A T ools Nee d e d : . For best wire feeding performance, be sure that the outlet cable has the proper size liner for the welding wire size being used. Also, when the gun is installed, the liner extending from the back of the gun shoul[...]

  • Page 18

    OM-1500-4 Page 14 3-7. Setting Internal DIP Switches Position Settings And Results For DIP Switch S1 On = Current detect over- ride. For welding power sources that don ’ t provide current feedback through the 14-pin receptacle. Fac- tory set automatic run-in is inactive. Off = Current must be detected from power sources that provide current feedb[...]

  • Page 19

    OM-1500-4 Page 15 T ools Needed: 1/4 in 3-8. Optional Equipment DIP Switch Settings 12 3 45 Or Or High Speed Motor Meters/Minute High Speed Motor Inches/Minute Standard Motor Meters/Minute Standard Motor Inches/Minute Digital Meter Functions 12 3 45 12 3 45 12 3 45 Ref. 802 946 Remove wrapper . Install wrapper when finished.[...]

  • Page 20

    OM-1500-4 Page 16 SECTION 4 – OPERA TION 4-1. Power Switch 1 Power Switch 1 802 827-A 4-2. Jog/Purge Pressing the Jog/Purge switch allows the op- erator to jog wire without energizing the weld power or gas valve circuit. • Th e unit also provides the ability to jog the wire feeder by means of the gun trigger , however , the contactor is energiz[...]

  • Page 21

    OM-1500-4 Page 17 4-3. T rigger Hold Switch 1 T rigger Hold Switch Trigger hold allows the operator to weld with- out holding the gun trigger . • T o use the trigger hold function, place the trigger hold switch in the On position. • T he operator must hold the trigger for a mini- mum of 2 seconds, but not longer than 6 seconds before releasing [...]

  • Page 22

    OM-1500-4 Page 18 SECTION 5 – MAINTENANCE 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. Check 14-pin cord. Check gas hose and fittings. Check gun cable. Replace cracked parts. 6 Months Blow out or vacuum inside. During hea[...]

  • Page 23

    OM-1500-4 Page 19 5-2. Diagnostics • Error Indications Error conditions are indicated by LED3 on PC 1 or on display if meter option is present. T o 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 indi[...]

  • Page 24

    OM-1500-4 Page 20 Notes[...]

  • Page 25

    OM-1500-4 Page 21 SECTION 6 – ELECTRICAL DIAGRAM Figure 6-1. Circuit Diagram 202 246[...]

  • Page 26

    OM-1500-4 Page 22 SECTION 7 – P ARTS LIST 802 943 . Hardware is common and not available unless listed. Fig 7-2 21 Fig 7-3 4 1 2 6 14 15 16 17 18 19 20 5 7 8 9 10 11 12 11 10 13 3 Figure 7-1. Main Assembly[...]

  • Page 27

    OM-1500-4 Page 23 Description Part No. Item No. Figure 7-1. Main Assembly Quantity 1 159 647 INSULA TOR, motor clamp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 159 646 CLAMP , motor base 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 28

    OM-1500-4 Page 24 802 945 . Hardware is common and not available unless listed. 1 2 3 5 6 4 6 5 7 8 9 10 12 13 14 15 16 17 18 20 21 22 23 24 19 Figure 7-2. Control Box Description Part No. Dia. Mkgs. Item No. Figure 7-2. Control Box (Figure 7-1 Item 14) Quantity 1 200 555 WRAPPER, feeder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 29

    OM-1500-4 Page 25 Description Part No. Dia. Mkgs. Item No. Figure 7-2. Control Box (Figure 7-1 Item 14) (Continued) Quantity 22 202 237 P ANEL, front (base unit) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 RC13 048 282 RCPT W/SKTS, (service kit) 1 . . . . . . . . . . .[...]

  • Page 30

    OM-1500-4 Page 26 See T able 9-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 802 950 1 2 3 4 5 6 7 8 10 9 11 12 13 14 16 17 18 19 20 21 23 24 6 5 4 3 2 1 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 15 22 Figure 7-3. Drive Assembly , Wire Description Part No. Dia. Mkgs. Item No. Figure 7-3. Drive Assem[...]

  • Page 31

    OM-1500-4 Page 27 Description Part No. Dia. Mkgs. Item No. Figure 7-3. Drive Assembly , Wire (Figure 7-1 Item 23) (continued) Quantity 17 182 155 SPRING 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 132 746 BUSHING, spring 2 . . . . . . . . [...]

  • Page 32

    OM-1500-4 Page 28 .023-.025 in. 0.6 mm 151 024 087 130 .030 in. 0.8 mm 151 025 053 695 .035 in. 0.9 mm 151 026 053 700 151 036 072 000 151 052 132 958 .045 in. 1.1/1.2 mm 151 027 053 697 151 037 053 701 151 053 132 957 151 070 083 489 .052 in. 1.3/1.4 mm 151 028 053 698 151 038 053 702 151 054 132 956 151 071 083 490 1/16 in. 1.6 mm 151 029 053 699[...]

  • Page 33

    OM-1500-4 Page 29 Notes[...]

  • Page 34

    OM-1500-4 Page 30 Notes[...]

  • Page 35

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y o ur distributor also gives you ... Service Y ou 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 [...]

  • Page 36

    PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 W est S pencer St reet Applet on, WI 54914 USA International He adquarters – USA USA Phone: 920-735-4505 Auto-A t t ended USA & Canada F AX : 920-735-4134 Int ernati onal FAX: 920-735-4125 European Headqua rters – United[...]