OM-1500-1
200 510A
May 2001
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
714D
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TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
5
5
5
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 &
Safety Code Section
25249.5 et seq.)
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
8
8
1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
10
10
SECTION 3 – INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-1. Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Rear Panel Connections And Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. 14-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Gun Recommendation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Wire Type, Size, And Feed Speed Capability Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Setting Internal DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
13
13
13
14
15
SECTION 5 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Program Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Upper Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Lower Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Setup Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Adjust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Sequence Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Auxiliary Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Jog/Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
17
18
18
19
19
20
20
22
24
SECTION 6 – SETTING SEQUENCE 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 8 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
27
SECTION 9 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 10 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Warranty
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
OM-1500-1
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Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
Note
Manufacturer’s Name:
Miller Electric Mfg. Co.
Manufacturer’s Address:
1635 W. Spencer Street
Appleton, WI 54914 USA
Declares that the product:
714D
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 Code): IEC 529
(November 1989 – First Edition)
Insulation Coordination For Equipment With Low-Voltage Systems:
Part I: Principles, Requirements and Tests: IEC 664-1
(October 1992 – First Edition)
Electromagnetic Compatibility, (EMC): EN 50199
(August 1995)
European Contact:
Mr. Danilo Fedolfi, Managing Director
MILLER Europe S.r.l.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
Telephone:
Fax:
39(02)98290-1
39(02)98281-552
dec_con 11/96
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
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.
Y
Marks a special safety message.
. Means “Note”; not safety related.
1-2. Arc Welding Hazards
Y
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.
D
D
D
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D
D
D
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Y
Y
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D
D
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
ELECTRIC SHOCK can kill.
Do not connect more than one electrode or work cable to any
single weld output terminal.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
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
groundedequipment is a hazard.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D
D
D
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
FUMES AND GASES can be hazardous.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
D
D
Use AC output ONLY if required for the welding process.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If AC output is required, use remote output control if present on
unit.
D
D
If ventilation is poor, use an approved air-supplied respirator.
D
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).
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D
D
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D
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.
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
groundedreceptacle outlet.
D
D
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.
D
D
When making input connections, attach proper grounding conduc-
tor first – double-check connections.
Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-suppliedrespirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
D
D
D
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.
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ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
D
D
Shut off shielding gas supply when not in use.
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.
Always ventilate confined spaces or use
approved air-supplied respirator.
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 Z87.1 listed in Safety Standards).
HOT PARTS can cause severe burns.
D
D
D
Wear approved safety glasses with side shields under your
helmet.
D
D
Do not touch hot parts bare handed.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Allow cooling period before working on gun or
torch.
Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
D
D
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
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.
NOISE can damage hearing.
D
D
D
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Noise from some processes or equipment can
damagehearing.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D
Wear approved ear protection if noise level is
high.
D
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D
D
Watch for fire, and keep a fire extinguisher nearby.
CYLINDERS can explode if damaged.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
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.
D
D
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
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.
D
D
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.
D
D
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.
D
D
D
D
D
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
D
D
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
FLYING METAL can injure eyes.
D
D
Turn face away from valve outlet when opening cylinder valve.
D
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
D
Wear approved safety glasses with side
shields even under your welding helmet.
OM-1500-1 Page 2
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D
Do not install or place unit on, over, or near
combustiblesurfaces.
D
D
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
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.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D
D
D
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Use equipment of adequate capacity to lift and
support unit.
D
Have only qualified persons familiar with
electronic equipment perform this installation.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
D
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
If notified by the FCC about interference, stop using the
equipmentat once.
OVERUSE can cause OVERHEATING
D
D
Allow cooling period; follow rated duty cycle.
D
D
Have the installation regularly checked and maintained.
Reduce current or reduce duty cycle before
starting to weld again.
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.
D
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
D
D
Put on grounded wrist strap BEFORE handling
boards or parts.
ARC WELDING can cause interference.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
MOVING PARTS can cause injury.
D
Be sure all equipment in the welding area is
electromagneticallycompatible.
D
D
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
D
D
D
D
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
WELDING WIRE can cause injury.
Be sure this welding machine is installed and grounded
according to this manual.
D
D
Do not press gun trigger until instructed to do
so.
If 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.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
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.
Recommended Safe Practices for the Preparation for Weldingand 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
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-1500-1 Page 3
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1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
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.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s 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.
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:
To reduce magnetic fields in the workplace, use the following
procedures:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-1500-1 Page 4
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT
UTILISATION
som _nd_fre 4/98
1-1. Signification des symboles
SignifieMise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
Y
Identifie un message de sécurité particulier.
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
. Signifie NOTA ; n’est pas relatif à la sécurité.
1-2. Dangers relatifs au soudage à l’arc
Y
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques
de danger. Lorsque vous voyez un symbole, soyez vigilant et
suivez les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité présentées ci-après ne font que résumer
l’information contenue dans les normes de sécurité énumérées
à la section 1-4. Veuillez lire et respecter toutes ces normes de
sécurité.
D
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
champ les pièces endommagées. Entretenir l’appareil conformément
à ce manuel.
D
D
D
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
Y
Y
L’installation, l’utilisation, l’entretien et les réparations ne doi-
vent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus par-
ticulièrement les enfants.
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
UN CHOC ÉLECTRIQUE peut tuer.
Il y a DU COURANT CONTINU IMPORTANT dans les
convertisseurs après la suppression de l’alimenta-
tion électrique.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est sur ON. Le circuit d’entrée et les
circuits internes de l’appareil sont également sous
D
Arrêter les convertisseurs, débrancher le courant électrique, et dé-
charger les condensateurs d’alimentation selon les instructions
indiquées dans la partie entretien avant de toucher les pièces.
tension à ce moment-là. En soudage semi-automatique ou automatique,
le fil, le dévidoir, le logement des galets d’entraînement et les pièces
métalliques en contact avec le fil de soudage sont sous tension. Des
matériels mal installés ou mal mis à la terre présentent un danger.
D
D
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant
pas de trous.
D
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact phy-
sique éventuel avec la pièce ou la terre.
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
D
D
D
D
inhalation peut être dangereux pour votre santé.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
D
Eloigner votre tête des fumées. Ne pas respirer
les fumées.
Si l’utilisation d’une source électrique àcourant électrique s’avère néces-
saire, se servir de la fonction de télécommande si l’appareil en est équipé.
D
A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau
de l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimenta-
tion d’air homologué.
Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal-
lation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
Installer et mettre à la terre correctement cet appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assu-
rer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas
endommagé ou dénudé – remplacer le cordon immédiatement s’il est
endommagé – un câble dénudé peut provoquer une électrocution.
D
D
Lire les spécifications de sécurité des matériaux (MSDSs) et les
instructions du fabricant concernant les métaux, les consomma-
bles, les revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un
surveillant dûment formé de se tenir à proximité. Des fumées et des
gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxy-
gène provoquant des blessures ou des accidents mortels. S’assu-
rer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de
dégraissage, de nettoyage ou de pulvérisation. La chaleur et les
rayons de l’arc peuvent réagir en présence de vapeurs et former des
gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit bien
ventilé, et si nécessaire, en portant un respirateur à alimentation
d’air. Les revêtements et tous les métaux renfermant ces éléments
peuvent dégager des fumées toxiques en cas de soudage.
D
D
D
D
D
D
D
D
D
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
D
D
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D
Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode provenant d’une autre machine.
OM-1500-1 Page 5
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LES RAYONS DE L’ARC peuvent pro-
voquer des brûlures dans les yeux et
sur la peau.
LES ACCUMULATIONS DE GAZ ris-
quent de provoquer des blessures ou
même la mort.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brûlures dans les yeux et sur la peau. Des étincelles sont projetées
pendant le soudage.
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
rateur d’adduction d’air homologué.
D
Porter un casque de soudage muni d’un écran de filtre approprié pour
protéger votre visage et vos yeux pendant le soudage ou pour regar-
der (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
DES PIÈCES CHAUDES peuvent pro-
voquer des brûlures graves.
D
D
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair
et de l’éblouissement; demander aux autres personnes de ne pas re-
garder l’arc.
Porter des vêtements de protection constitué dans une matière dura-
ble, résistant au feu (cuir ou laine) et une protection des pieds.
D
D
Ne pas toucher des parties chaudes à mains nues
Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
D
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent être
projetées de l’arc de soudure. La projection d’étincel-
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D
D
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
les, des pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
D
D
D
Se protéger et d’autres personnes de la projection d’étincelles et de
LE BRUIT peut affecter l’ouïe.
métal chaud.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur
des substances inflammables.
Le bruit des processus et des équipements peut affecter
l’ouïe.
Déplacer toutes les substances inflammables à une distance de 10,7
m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneuse-
ment avec des protections homologués.
Des étincelles et des matériaux chauds du soudage peuvent facile-
ment passer dans d’autres zones en traversant de petites fissures et
des ouvertures.
D
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
D
D
D
D
Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-
Si des BOUTEILLES sont endomma-
gées, elles pourront exploser.
mité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endomma-
gée, elle peut exploser. Du fait que les bouteilles de gaz
font normalement partie du procédé de soudage, les
Ne pas effectuer le soudage sur des conteneurs fermés tels que des
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été prépa-
rés correctement conformément à AWS F4.1 (voir les normes de
sécurité).
Brancher le câble sur la pièce le plus près possible de la zone de sou-
dage pour éviter le transport du courant sur une longue distance par
des chemins inconnus éventuels en provoquant des risques d’élec-
trocution et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
lées.
En cas de non utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans re-
vers, des chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches
telles qu’un allumeur au butane ou des allumettes.
manipuler avec précaution.
D
D
D
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, du laitier, des flammes ouvertes, des étin-
celles et des arcs.
Placer les bouteilles debout en les fixant dans un support stationnai-
re ou dans un porte-bouteilles pour les empêcher de tomber ou de
se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres cir-
cuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une
D
D
D
D
D
bouteille.
D
D
D
Ne jamais souder une bouteille pressurisée – risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D
D
D
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’uti-
lisation ou de branchement de la bouteille.
Lire et suivre les instructions concernant les bouteilles de gaz com-
primé, les équipements associés et les publications P-1 CGA énu-
mérées dans les normes de sécurité.
D
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques vo-
lantes. Pendant la période de refroidissement des soudures, elles ris-
quent de projeter du laitier.
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
OM-1500-1 Page 6
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Ne pas placer l’appareil sur, au-dessus ou à proxi-
mité de surfaces infllammables.
D
D
Rester à l’écart des organes mobiles comme le
ventilateur.
Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
D
D
Ne pas installer l’appareil à proximité de produits inflammables
Ne pas surcharger l’installation électrique – s”assurer que l’alimen-
tation est correctement dimensionné et protégé avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
D
Le rayonnement haute frequence peut provoquer
des interférences avec les équipements de ra-
dio–navigationet de communication, les services
de sécurité et les ordinateurs.
D
D
Utiliser l’anneau de levage uniquement pour sou-
lever l’appareil, NON PAS les chariot, les bouteil-
les de gaz ou tout autre accessoire.
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installa-
tion.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Utiliser un engin d’une capacité appropriée pour
soulever l’appareil.
D
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
D
D
Si le FCC signale des interférences, arrêter immédiatement l’appa-
reil.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blindage pour réduire les interfé-
rences éventuelles.
D
D
Prévoir une période de refroidissement, respec-
ter le cycle opératoire nominal.
Réduire le courant ou le cycle opératoire avant de
recommancer le soudage.
LE SOUDAGE À L’ARC risque de
D
Ne pas obstruer les passages d’air du poste.
provoquer des interférences.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les
circuits imprimés.
D
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
D
D
Veiller à ce que tout l’équipement de la zone de soudage soit com-
D
D
Établir la connexion avec la barrette de terre
patible électromagnétiquement.
avant de manipuler des cartes ou des pièces.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires tel-
les que le déplacement du poste, l’utilisation de câbles blindés, l’uti-
lisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
D
D
D
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
D
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D
D
Porteurs de stimulateur cardiaque, restez à dis-
D
D
Ne pas appuyer sur la gachette avant d’en avoir
reçu l’instruction.
tance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’appro-
cher des opérations de soudage à l’arc, de gou-
geage ou de soudage par points.
Ne pas diriger le pistolet vers soi, d’autres person-
nes ou toute pièce mécanique en engageant le fil
de soudage.
OM-1500-1 Page 7
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1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126
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.
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
RecommendedSafe Practice for the Preparation 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
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.
NationalElectrical Code, NFPA Standard 70, de la National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Le courant de soudage, pendant son passage dans les câbles de sou-
dage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir ex-
aminé plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Re-
search Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiqueset champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les con-
clusions finales de la recherche soient établies, il vous serait
souhaitablede réduire votre exposition aux champs électromagnéti-
ques pendant le soudage ou le coupage.
2
3
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4
5
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près 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 êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
OM-1500-1 Page 8
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SECTION 2 – DEFINITIONS
2-1. Warning Label Definitions
A. Warning! Watch Out! There
are possible hazards as
shown by the symbols.
B. Drive rolls can injure fingers.
A
B
C
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
2
1.1
2.1
3.1
4.1
1.2
1.3
1.3 Disconnect input plug or
power before working on
machine.
2
Breathing welding fumes can
be hazardous to your health.
2.2
2.3
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
4
5
3.2
3.3
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.
6
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.
+
S-178 936
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
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2-2. Rating Label For CE Products
For label location
see Section 4-2.
S/N:
U1
50/60 Hz
IP 21
24 V
10.0A
1
=
I =
1
U2
=
I =
750 A
2
100 V
X 100 %
ST-178 794-A
2-3. Symbols And Definitions
Some symbols are found only on CE products.
Note
Amperes
Volts
AlternatingCurrent
Program
Duty Cycle
A
IP
V
Hz
X
Degree Of
Protection
Hertz
Wire Feed
Jog
Output
Trigger
Line Connection
Set Up
Sequence
Trigger Hold On
Trigger Hold Off
Crater
Purge
Time
Press To Set
Preflow Time
Start
Postflow Time
Rated Current
Read Instructions
Load Voltage
Increase
Primary Current
Dual Schedule
I1
I2
U2
A
B
Primary Voltage
U1
OM-1500-1 Page 10
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SECTION 3 – INTRODUCTION
3-1. Specifications
Wire
Diameter
Range
Welding
Circuit
Rating
Type of Input
Power
Welding Power
Source Type
Wire Feed
Speed Range
IP
Rating
Overall
Dimensions
Weight
24 Volts AC
Single-Phase
10 Amperes
50/60 Hertz
Constant Voltage (CV)
DC With 14-Pin And
Contactor Control
Standard: 50 To
780 ipm (1.3 To
19.8 mpm)
.023 To 1/8 in
(0.6 To 3.2
mm)
100 Volts,
750
Amperes,
100% Duty
Cycle
IP 21
Length: 27 in
(686 mm)
58 lb
(26 kg)
Width: 12-1/2 in
(318 mm)
Optional High
Speed: 90 To
1440 ipm (2.3 To
36.6 mpm)
Max Spool
Weight: 60 lb
(27 kg)
Height: 14 in
(356 mm)
SECTION 4 – INSTALLATION
4-1. Site Selection
1
2
Wire Feeder
Rubber Feet
Choose slot that allows all rubber
feet to sit securely on top of welding
power source.
3
4
3
4
Wire Spool/Reel
Gas Cylinder w/Hose And Re-
gualtor (Customer Supplied)
1
5
Welding Power Source
Running Gear
6
5
Y
Do not put feeder where
welding wire hits cylinder.
Y
Do not move or operate
equipmentwhen it could tip.
2
. 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.
6
Ref. ST-152 468-A / ST-152 467-C
OM-1500-1 Page 11
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4-2. Rear Panel Connections And Rotating Drive Assembly
1
2
14-Pin Control Cable – 10’
Shielding Gas Valve Fitting
Requires fitting with 5/8-18 right-
hand threads. Connect customer-
supplied gas hose.
3
4
5
6
Weld Cable Terminal
Weld Cable
Drive Assembly
Drive Assembly Rotation
Knob
To rotate the drive assembly, loos-
en drive assembly rotation knob,
rotate drive assembly, and tighten
knob.
2
1
3
4
5
6
Tools Needed:
9/16, 5/8 in
3/16 in
802 824-A / 802 825-A
OM-1500-1 Page 12
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4-3. 14-Pin Plug Information
Pin*
Pin Information
A
B
G
C
D
E
H
F
24 volts ac with respect to socket G.
Contact closure to A completes 24 volts ac contactor control circuit.
Circuit common for 24 volts AC circuit.
J
A
K
I
B
C
L
H
N
+10 volts dc input from power source to wire feeder with respect to socket D.
Remote control circuit common.
M
E
G
D
F
0 to +10 volts dc output signal from wire feeder to power source with respect to socket D.
Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.
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
Standard
Wire Type
Wire Size
Feed Speed Capability
All
All
All
.023 To 5/64 in (0.6 To 2 mm)
3/32 To 7/64 in (2.4 To 2.8 mm)
1/8 in (3.2 mm)
50 To 780 ipm (1.3 To 19.8 mpm)
50 To 700 ipm (1.3 To 17.8 mpm)
50 To 300 ipm (1.3 To 7.6 mpm)
Standard
Standard
Optional High
Speed
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
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4-6. Installing And Threading Welding Wire
Install wire guides and
anti-wear guide.
Install wire spool. Adjust tension nut so
wire is taut when wire feed stops.
Install drive rolls.
Pressure
Indicator
Scale
Pressure
Adjust
Rear
Rolls
Pressure
Adjust
Front
Rolls
No Wire Slip
Wire Slips
NONCONDUCTIVE
SURFACE
NONCONDUCTIVE
SURFACE
Drive Rolls
Gun Cable
Tools Needed:
3/16, 5/64 in
15/16, 3/8 in
End Of Liner
. Be sure that outlet cable has proper size . For soft wire or small diameter stainless . To adjust drive roll pressure, hold nozzle
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.
steel wire, reduce drive roll pressure on
the rear roll to half that of the front rolls.
about 2 in (51 mm) from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire
does not slip. Do not overtighten. If con-
tact tip is completely blocked, wire should
slip at the feeder (see pressure adjust-
ment above).Cut wire off. Close cover.
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.
Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / 802 954 / S-0627-A
OM-1500-1 Page 14
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4-7. Setting Internal DIP Switches
1
O
N
1
2
3
4
5
6
7
8
. 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.
. 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.
2
802 808
Position Settings And Results For DIP Switch S1
1
2
3
4
3
4
*
On = Front panel display
shows wire feed speed in
meters per minute.
3 Off, 4 Off = Range limit-
ing disabled (locks Off).
3 On, 4 Off = Range limit
on voltage and wire feed
speed set at ±5%.
On = Front panel display
shows weld amperage
during welding.
1
5
2
6
3
7
4
8
3
7
4
8
Off = Front panel display
shows wire feed speed
during welding.
Off = Front panel display
shows wire feed speed in
inches per minute.
3 Off, 4 On = Range limit
on voltage and wire feed
speed set at ±10%.
3 On, 4 On = Range limit
on voltage and wire feed
speed set at ±20%.
On = Current detect overri-
de. For welding power
sources that don’t provide
current feedback through
the 14-pin receptacle.
7 Off, 8 Off = Normal
speed motor (50–780
inches per minute)
7 On, 8 Off = Reserved
for future use.
On = Front panel display
holds weld parameters
for 5 seconds following
trigger release.
5
6
7
8
7
8
Off = Front panel display
returns to preset upon trig-
ger release.
Off = Current must be de-
tected to go from run-in to
welding condition.
7 Off, 8 On = High speed
motor (90–1440 inches
per minute)
7 On, 8 On = Reserved
for future use.
1
2
DIP Switch S1
DIP Switch S4 (Not For Customer Use)
ing unit settings, but still allows some level of Trigger Hold and Dual Schedule function nor-
adjustmentthrough the Adjust control. When mally when locks are enabled.
a lock position is used, the lock applies to all
DIP switch S1 allows the user to make a num-
ber of choices affecting unit operation.
w Setting Display Hold Feature (S1-5)
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 ±5%,
Locks On ±10%, and finally Locks On ±20%.
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.
w 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.
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.
w 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.
. To changing Lock %, proceed as follows:
w Selecting Wire Feed Speed Value (S1-2)
Turn power Off
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.
Place DIP switches S1-3&4 in the Off position
(see *3&4 above)
w Defining Motor Speed (S1-7 & 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
(90–1440inches per minute).
Turn power On and Off
Place switches 3&4 in desired new settings
w Adjusting Range Limits (S1-3 & 4)
The lock feature provides a means of regulat- Turn power On and Off.
OM-1500-1 Page 15
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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
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.
Weld Program
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.
5-2. Power Switch
1
1
Power Switch
802 809-A
OM-1500-1 Page 16
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5-3. Front Panel Controls
Nameplate For Non-CE Models
See
Section
5-5
See
Section
5-4
Program
See
Section
5-6
Volts
Time (sec)
Wire Speed
Amps
Start
Dual Schedule
Trigger Hold
Crater
Pre/Postflow
Sequence
Adjust
Setup
See
Section
5-9
See
Section
5-8
See
Section
5-7
Nameplate For CE Models
See
Section
5-5
See
Section
5-4
See
Section
5-6
See
Section
5-7
See
Section
5-9
See
Section
5-8
OM-1500-1 Page 17
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5-4. Program Push Button
1
Program Display
Non-CE Models
CE Models
The number of the active program
is displayed.
2
Program Push Button
Press button to activate program
select feature. To change the pro-
gram number, press the Program
push button and rotate the Adjust
control.
1
1
2
3
Program Push Button LED
Program
3
The LED lights to indicate the Pro-
gram push button is active.
3
2
5-5. Upper Display
. 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.
Non-CE Models
3
2
1
4
Volts
Time (sec)
5
CE Models
3
2
1
4
5
1
Upper Display
The LEDs below the display illuminate to in-
dicate which value is being shown.
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 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.
At any time while welding, the unit permits
the adjustment of the weld sequence voltage
and overrides the display of actual arc volt-
age.
• The unit defaults to displaying welding
voltage when a welding sequence display
mode is first entered. When the unit is in a
welding state, the welding time display
mode is terminated in place of the voltage
display mode.
• If 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. Preset voltage is de-
fined as the desired arc voltage com-
manded to the welding power source.
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.
• 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.
• 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
4
5
Volts LED
Time LED
OM-1500-1 Page 18
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5-6. Lower Display
3
2
1
Non-CE Models
4
Wire Speed
Amps
5
3
1
4
2
CE Models
5
1
Lower Display
nates to indicate that information displayed
can be changed by the Adjust control.
ment of the weld sequence wire feed
speed regardless of the active welding se-
quence.
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.
4
5
Wire Speed LED
Amps LED
• 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 LEDs below the display illuminate to in-
dicate which value is being shown.
• If the unit is in a welding state that does not
involve feeding wire, the unit displays the
2
Lower Display Push Button
weld sequence wire speed. At any time • The display will read zero for amperage
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-
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).
Press button to choose between wire speed
or amperage functions.
3
Lower Display Push Button LED
The lower display push button LED illumi-
5-7. Setup Push Button
3
3
4
Trigger Hold
4
2
Dual Schedule
2
1
1
Setup
Non-CE Models
CE Models
1
Setup Push Button
tus On/Off. Use the Adjust control to change • When the Setup button is pressed a second
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.
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.
Press button to choose between trigger hold
or dual schedule functions.
2
3
4
Setup Push Button LED
Trigger Hold LED
• When trigger hold is On, the user must
press and hold the trigger for a predefined
amountof 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.
• Pressing the Setup button again exits the
Setup mode. The dual schedule LED stops
flashingto indicate the dual schedule status
is Off.
Dual Schedule LED
• When the Setup button is pressed, the Set-
up push button LED illuminates and the Trig-
ger Hold LED flashes.
• While in the Setup mode, the active program
can be adjusted without deactivating the
trigger hold Setup mode operation. If the
trigger is activated, Setup mode(s) is termi-
nated.
• The flashing LED indicates that the unit is in
the trigger hold display mode. In this mode
the upper display indicates HOLD and the • If a weld time is programmed, trigger hold is
lower display indicates the trigger hold sta- disabled.
OM-1500-1 Page 19
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5-8. Adjust Control
1
Adjust Control
The Adjust control is used to
change various sequence parame-
ters, and to select various se-
quences. Refer to the section for
the function in question for informa-
tion related to using the Adjust con-
trol.
1
1
Adjust
Non-CE Models
CE Models
5-9. Sequence Push Button
1
2
3
Sequence Push Button
Sequence Push Button LED
Welding Sequence LEDs
Start
3
3
Crater
Pre/Postflow
Weld
2
1
Start
Time
Crater
Time
2
Time
Preflow
Time
1
Postflow
Time
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.
quence except for Weld, that sequence will • When the Sequence push button is pressed
be skipped.
a third 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.
• 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.
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.
• 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 mode is activated.
• 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 • When the Sequence push button is pressed
remains illuminated. In this condition, the
unit is in the Crater sequence display mode,
and Crater sequence parameters are
shown in the displays.
a fourth time, all sequence LEDs and the
Sequence push button LED go off and the
unit returns to the welding sequence display
mode.
If zero time is programmed for a timed se-
OM-1500-1 Page 20
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Notes
OM-1500-1 Page 21
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5-10. Auxiliary Menus
Non-CE Models
4
5
7
1
2
Program
Volts
Time (sec)
Wire Speed
Amps
6
Start
Trigger Hold
Crater
Pre/Postflow
Dual Schedule
9
3
Sequence
Adjust
Setup
8
CE Models
4
5
1
2
7
6
9
3
8
OM-1500-1 Page 22
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1
2
3
4
5
6
7
8
9
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
Auxiliary Menu
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).
hold. Trigger hold delay time is the minimum
amountof time the trigger must be held for trig-
ger hold to work when the trigger is released
(the trigger hold function must be on). For ex-
ample, if a trigger hold delay time of 2.0 sec-
onds is defined, the operator must hold the
trigger for at least 2 seconds before releasing
it in order for the trigger hold function to work.
Once the trigger hold function is in effect, the
wire feeder will stay On until the trigger is
pressed and released again.
• 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.
V-Min And V-Max
• If the Setup push button is pressed, the unit
allows the setting of the manual override
power source min and max voltage preset
range. The minimum voltage is displayed in
the upper display and the lower display indi-
cates “VMIN”. When the Setup push button
is pressed the unit displays the maximum
voltage setting of the welding power source.
The maximum voltage is displayed in the
upper display and the lower display indi-
cates “VMAX”.
. The auxiliary menu may be exited at any
time by pressing both the Sequence push
button and the Setup push buttons simul-
taneously.
• 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.
Run-In
• The Setup push button is used to step
throughmenu 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.
In both cases, the Adjust control is used to
specify the minimum and maximum voltage
settings of the welding power source. The set-
tings correspond to arc voltage obtained at
minimumcommand and arc voltage obtained
at maximum command.
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 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.
Arc Time
• When the Setup push button is pressed
again, the menu repeats to the first menu
selection of run-in wire speed selection.
• If the Setup push button is pressed, the unit
displays arc time in hours.
Arc time is indicated by the Program display
showing “HR”. Arc time is shown in the lower
display.
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
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 oneĆ
half weld sequence wire speed.
Cycles
• If 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.
Burnback
Trigger Hold Setup
• If the Setup push button is pressed, the unit
allows burnback time to be set.
• If the Setup push button is pressed, the unit
allows trigger hold delay time to be set.
Burnback time and voltage can be specified
when the lower display indicates “BURN” and Trigger hold delay time is indicated by ”HOLD”
the upper display indicates the burnback time in the lower display and the hold delay time in display to “WIPE OFF” and simultaneously
or voltage. The Adjust control is used to set the the upper display. The adjust control can be
desired burnback time or voltage. Burnback used to specify a new delay time for trigger
press the Program, Sequence, upper display,
and Setup push buttons to exit the reset menu.
OM-1500-1 Page 23
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5-11. Jog/Purge
1
2
3
Jog/Purge Push Button
Adjust Control
Gun Trigger Receptacle
2
3
802 807
1
Pressing the Jog/Purge switch allows the op-
erator to jog wire without energizing the weld
power or gas valve circuit.
jog operation is terminated to prevent com-
plete despooling of the wire, in the case of
a damaged gun. This function is not avail-
able if current detect override is enabled
(DIP switch S1-6 is in On position).
control when the unit is jogging wire. The
unit displays jog speed when the unit is be-
ing jogged.
• The unit provides the ability to jog the wire
feeder by means of the gun trigger or the
Jog/Purge switch. If the welding arc does
not initiate in 3 seconds after the gun trigger
is activated, the unit will perform a jog opera-
tion for a maximum of two minutes. If the gun
• Jogging can also be accomplished by
pressing the Jog/Purge button.
• The unit displays the “ERR TRIG“ message
to inform the operator that the trigger is acti-
vated.
• Pressing the Jog/Purge button also allows
the operator to purge gas lines before weld-
ing and to preset gas pressure at the
regulator.
trigger is still activated after two minutes, the • Jog speed can be adjusted by the Adjust
OM-1500-1 Page 24
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SECTION 6 – SETTING SEQUENCE PARAMETERS
6-1. Sequence Parameters In A Program
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.
Sequence
Parameters
Volts
IPM
Seconds
0-9.9
1. Preflow
2. Run-In
3. Start
4. Weld
X
X
X
X
X
X
X
X
0.00-5.00
0-100.0
0-5.00
5. Crater
6. Burnback
7. Postflow
0-0.25
0-9.9
X = Setting available.
Weld Time
Crater
Time
Burnback
Time
Start
Time
Preflow
Time
Postflow
Time
Time
Burnback
Sequence
End
Run-In
Weld
Start
Crater
Postflow
Preflow
Trigger
Released
Trigger
Pressed
OM-1500-1 Page 25
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SECTION 7 – SETTING DUAL SCHEDULE PARAMETERS
7-1. Optional Dual Schedule Switch Diagrams
1
2
Maint 2P (Maintained-Contact
2-Pole Switch)
1
2
Maint 1P (Maintained-Contact
1-Pole Switch)
1
2
DSS-9
1
DSS-8
1
2
2
3
TR
B
A
3
4
A
4
B
SECTION 8 – MAINTENANCE
8-1. Routine Maintenance
Y
Disconnectpower before maintaining.
3 Months
Clean and
tighten
weld
Repair or
replace
cracked
weld
Replace
unreadable
labels.
terminals.
cable.
Replace
cracked
parts.
Check
14-pin cord.
Check gas
hose and
fittings.
Check gun
cable.
6 Months
Blow out or vacuum
inside. During heavy
service, clean
Clean
drive rolls.
Or
monthly.
OM-1500-1 Page 26
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8-2. Diagnostics
1
2
3
4
Wrapper
Motor Control Board PC1
LED3
DIP Switch S1
. 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.
2
3
1
4
Front panel is shown removed for purpose of
illustration only. In actual use, front panel
would be in place.
Ref. 802 687
The following error messages are shown on the
upper and lower displays to indicate specific errors.
Explanations are in the text below:
ERR
ERR
ERR
ERR
MTR
ERR
GAS
ERR
COMM
TRIG
TACH
COOL
Indicates a
communication
error.
Indicates a trigger
error.
Indicates a
tachometer error.
Indicates a motor
error.
No gas flow
detected.
No coolant flow
detected.
LED3-RelatedError Indications
1 blink = Communication Error
2 blinks = Trigger Error
3 blinks = Tach Error
• The tach error occurs 2 seconds after the
loss of tachometer feedback. The user may
continue to weld with this error. The motor
speed is regulated through the monitoring of
voltage and current.
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.
4 blinks = Motor Error
• The communication error occurs 2.5 sec- • The motor error indicates that the motor
The LED blinks in a 2.5 second cycle. The
number of blinks in this period indicates the
type of error.
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).
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.
The priority of the errors is related to the num-
ber of blinks indicating the error. The more
blinks, the more severe the error (motor error
is top priority). A higher priority error overrides
a lower one (if a motor error and a communica-
tion error existed, the light would blink four
times for the motor error).
Additional Error Messages (Additional
hardware required for these to be
functional)
• 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
Gas flow error: indicates no gas flow is de-
tected. Connect a gas supply or remedy the
problems not allowing gas to flow.
weld. This error also occurs if the trigger is Coolant flow error: indicates no coolant flow is
held when the feeder is powered up. The er- detected. Connect a coolant system or reme-
ror may be cleared by releasing the trigger. dy the problems not allowing coolant to flow.
Since blink On time and blink Off time are
equal in a four-blink cycle, the four–blink se-
quence appears as a constant blink.
OM-1500-1 Page 27
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SECTION 9 – ELECTRICAL DIAGRAM
Figure 9-1. Circuit Diagram
200 592-C
OM-1500-1 Page 28
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Notes
OM-1500-1 Page 29
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SECTION 10 – PARTS LIST
6
. Hardware is common and
not available unless listed.
7
5
8
9
10
11
12
11
10
13
15
16
4
17
14
Fig 9-3
3
2
1
18
19
20
21
Fig 9-2
802 712-A
Figure 10-1. Main Assembly
OM-1500-1 Page 30
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Item
No.
Part
No.
Description
Quantity
Figure 10-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . 159 647 . . INSULATOR, motor clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 159 646 . . CLAMP, motor base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 159 360 . . INSULATOR, screw machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . . . . . . . . . . . . . . Fig 9-3 . . DRIVE ASSEMBLY, wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 141 753 . . HUB & SPINDLE ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 058 427 . . . . RING, retaining spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 180 571 . . . . SHAFT, support spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 010 233 . . . . SPRING, cprsn .970 OD x .120 wire x 1.250pld . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 057 971 . . . . WASHER, flat stl keyed 1.500dia x .125thk . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 010 191 . . . . WASHER, fbr .656 ID x 1.500 OD x .125thk . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . . . . . . 058 628 . . . . WASHER, brake stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . . 058 428 . . . . HUB, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 135 205 . . . . NUT, stl slflkg hex reg .625-11 w/nylon insert . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 200 556 . . SUPPORT, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . 201 781 . . KNOB, w/extension clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 156 243 . . CLAMP, motor top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 145 639 . . STRIP, buna N compressed sheet .062 x 4.000 x 4.000 . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 200 552 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . 134 306 . . FOOT, rubber 1.250 dia x 1.375 high no 10 screw . . . . . . . . . . . . . . . . . . 4
. . . 20 . . . . . . . . . . . . . . . 200 557 . . STIFFENER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . 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
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. Hardware is common and
not available unless listed.
1
4
8
11
10
9
13
3
12
10
11
2
7
23
5
6
14
22
18
15
19
20
21
16
17
802 802-A
Figure 10-2. Control Box
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-2. Control Box (Figure 10-1 Item 14)
. . . 1 . . . . . . . . . . . . . . . 200 555 . . WRAPPER, feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 200 153 . . OVERLAY, upper front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 204 762 . . OVERLAY, upper front panel (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 200 693 . . CIRCUIT CARD ASSY, switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 200 691 . . PANEL, pc card display/micro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 200 551 . . ENCLOSURE, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 134 201 . . STAND–OFF SUPPORT, pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 7 . . . . . . . . . . . . . . . 200 554 . . ENCLOSURE, motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 010 494 . . BUSHING, snap–in nyl 1.375 id x 1.750 mtg hole . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 057 357 . . BUSHING, snap–in nyl .937 id x 1.125 mtg hole . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 200 196 . . CABLE, power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 163 519 . . . . CABLE, port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 ft
. . . 11 . . . . . . . . . . . . . . . 139 041 . . . . STRAIN RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 079 739 . . . . CONN, circ cpc clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . PLG12 . . . . 141 162 . . . . HOUSING PLUG+PINS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG52 . . . . 174 823 . . . . HOUSING PLUG PINS+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . . 115 093 . . . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 605 227 . . NUT, 750–14 knurled1.68dia .41h nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . 200 333 . . VALVE, 34 VDC 2 way custom port 1/8 orf . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . L1 . . . . . . 203 197 . . INDUCTOR, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . PC1 . . . . . 201 549 . . CIRCUIT CARD ASSY, motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . S1 . . . . . . 111 997 . . SWITCH, rocker spst 10A 250 VAC on–off . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . 200 559 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-1500-1 Page 32
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-2. Control Box (Figure 10-1 Item 14) (Continued)
. . . 20 . . . . . S2 . . . . . . 200 295 . . SWITCH, rocker spdt 15A 12V (on)–off–(on) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 202 587 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 204 691 . . NAMEPLATE, (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 179 851 . . KNOB, pointer 1.670 dia x .250 id push on w/spring . . . . . . . . . . . . . . . . 1
. . . 23 . . . . RC13 . . . . . 048 282 . . RCPT W/SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . . 115 094 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG11,61 . . . 131 005 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . . . 202 592 . . HOUSING PLUG PINS+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG51 . . . . 174 824 . . HOUSING PLUG PINS+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . . 136 810 . . HOUSING PLUG PINS+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG7,27 . . . 115 091 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . . . 130 203 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 134 646 . . LABEL, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 178 936 . . LABEL, Warning General Precautionary Wordless CE . . . . . . . . . . . . . . 1
Detach Option
. . . . . . . . . . . . . . . . . . . . . 200 562 . . WRAPPER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 204 019 . . WRAPPER, motor box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 145 338 . . ANGLE FOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 604 311 . . GROMMET, rbr .250ID x .375 mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . 000 527 . . BLANK, snap-in nyl .875 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 192 465 . . BLANK, snap-in nyl .813 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 070 371 . . BLANK, snap-in nyl 1.125 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 024 376 . . BLANK, snap-in nyl .625 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 163 520 . . CABLE, port no 18-14 11/c type AWM 2-14 9-18 CND CT . . . . . . . . . . 25ft
. . . . . . . . . . . . . . . . . . . . . 079 739 . . CONN, circ cpc clamp str rlf size 17-20 .703 OD . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG44 . . . . 148 389 . . HOUSING PLUG PINS+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG45 . . . . 131 203 . . HOUSING PLUG PINS+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . RC40, 37 . . . 047 637 . . HOUSING RECPT+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG46 . . . . 115 090 . . HOUSING PLUG PINS+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG34 . . . . 136 810 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG35 . . . . 131 204 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG6, 36 . . . 115 094 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG37, 38 . . 047 636 . . HOUSING PLUG PINS+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC13 . . . . . 080 328 . . RCPTw/SKTS, free-hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 203 423 . . BUSHING, strain relief .300/.360 ID x .689 sq mtg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 604 571 . . CABLE, port no 18 4/c type sjo nprn jkt re . . . . . . . . . . . . . . . . . . . . . . . . . 2ft
OM-1500-1 Page 33
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13
. Hardware is common and
14
not available unless listed.
15
16
17
18
See Table 9-1 For
Drive Roll & Wire Guide Kits
19
20
9
7
8
6
5
4
3
21
2
12
1
22
10
11
23
24
39
25
26
27
28
38
37
36
29
35
30
6
5
34
31
32
33
4
3
2
1
802 950
Figure 10-3. Drive Assembly, Wire
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-3. Drive Assembly, Wire (Figure 10-1 Item 23)
. . . 1 . . . . . . . . . . . . . . . 010 668 . . SCREW, cap stl sch .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 2 . . . . . . . . . . . . . . . 172 075 . . CARRIER, drive roll w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 3 . . . . . . . . . . . . . . . 149 962 . . SPACER, carrier drive roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . . . . . . . . . . . . . 149 486 . . PIN, rotation arm rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . . 132 750 . . ARM, pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . . 150 520 . . SPACER, flat stl .257 ID x .619 OD x .105 . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . 133 493 . . RING, retaining ext .250 shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . . 133 350 . . PIN, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . M1 . . . . . . 201 230 . . MOTOR, gear 1/8hp 24VDC standard speed . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . M1 . . . . ♦201 231 . . MOTOR, gear 1/8hp 24VDC high speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 153 491 . . . . KIT, brush replacement (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 153 492 . . . . . CAP, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . *153 493 . . . . . BRUSH, carbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 184 136 . . . . KIT, brush holder replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 155 098 . . KIT, cover motor gearbox (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 153 550 . . . . COVER, motor gearbox (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 155 099 . . . . . GASKET, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 155 100 . . . . . SCREW, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . 154 031 . . . . SPACER, locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 133 493 . . . . RING, rtng ext .250 shaft grv x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 173 837 . . PRESSURE ARM (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 182 414 . . . . WASHER, flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 182 415 . . . . PIN, cotter hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 203 640 . . . . KNOB, w/extension short pressure arm . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 602 200 . . . . WASHER, lock stl split No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . 604 772 . . . . WASHER, flat stl SAE No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 182 156 . . . . SPRING, cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OM-1500-1 Page 34
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-3. Drive Assembly, Wire (Figure 10-1 Item 23) (contin-
ued)
. . . 17 . . . . . . . . . . . . . . . 182 155 . . . . SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . . 132 746 . . . . BUSHING, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . . 181 522 . . . . SHAFT, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . 132 747 . . . . CARRIER, shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 133 739 . . . . WASHER, flat buna .375 ID x .625 OD x .062thk . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 203 637 . . . . KNOB, w/extension long pressure arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . PC51 . . . . . 201 225 . . CIRCUIT CARD, digital tach (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG5 . . . . . 131 204 . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 604 311 . . . . GROMMET, rbr .250 ID x .375mtg hole .062 groove . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . 132 611 . . OPTICAL ENCODER DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 603 115 . . WEATHER STRIPPING, adh .125 x .375 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 167 387 . . SPACER, locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . . . 168 825 . . DRIVE, pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . 133 308 . . RING, retaining ext .375 shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 134 834 . . HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 2ft
. . . 29 . . . . . . . . . . . . . . . 149 959 . . FITTING, brs barbed M 3/16tbg x .312-24 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . 179 265 . . ADAPTER, gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . 108 940 . . SCREW, cap stl hexhd .250-20 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 32 . . . . . . . . . . . . . . . 604 538 . . WASHER, flat stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . 151 437 . . KNOB, plstc T 1.125 lg x .312-18 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . 151 290 . . SCREW, mach stl hexwhd 10-32 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . . . . . . 179 277 . . COVER, drive roll (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 178 937 . . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . . 601 872 . . NUT, stl hex full fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . 602 213 . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . . 602 243 . . WASHER, flat stl std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . 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
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G u i d e
I n t e r m e d i a t e
G u i d e
I n l e t
OM-1500-1 Page 36
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Effective January 1, 2000
(Equipment with a serial number preface of “LA” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
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.
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate 185 & Spoolmate 250
Canvas Covers
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.
Your distributor also gives
you ...
Miller’s True Blue Limited Warranty shall not apply to:
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
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.
2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Support
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.
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.
1. 5 Years Parts – 3 Years Labor
*
*
Original main power rectifiers
Inverters (input and output rectifiers only)
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.
2. 3 Years — Parts and Labor
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
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.
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
3. 1 Year — Parts and Labor
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
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
Grids
Maxstar 140
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
Spot Welders
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.
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
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.
*
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.)
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.
4. 6 Months — Batteries
5. 90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
miller_warr 7/00
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Service
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
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
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
manufacturer’s Transportation Department.
PRINTED IN USA
2001 Miller Electric Mfg. Co. 1/01
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