Instruction/ maintenance manual of the product OM-1500-4 Miller Electric
Go to page of 36
Visit our website at www.MillerWelds.com 714S Processes Description MIG (GMA W) W elding Flux Cored (FCA W) W elding (Gas- And Self-Shielded) Wire Feeder OM-1500-4 203 211 June 2001.
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
The following terms are used interchangeably throughout this manual: TIG = GT AW Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . .
.
OM-1500-4 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message.
OM-1500-4 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.
OM-1500-4 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit.
OM-1500-4 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields.
OM-1500-4 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives.
OM-1500-4 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage.
OM-1500-4 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables.
OM-1500-4 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American Wel- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.
OM-1500-4 Page 9 SECTION 2 – INTRODUCTION 2-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating IP Rating Overall Dim.
OM-1500-4 Page 10 SECTION 3 – INST ALLA TION 802 806-A 1 Wire Feeder 2 Rubber Feet Choose slot that allows all rubber feet t o sit securely on top of welding power source. 3 Wire Spool/Reel 4 Gas Cylinder w/Hose And Re- gualtor (Customer Supplied) 5 W elding Power Source 6 Running Gear Y Do not put feeder where welding wire hits cylinder .
OM-1500-4 Page 1 1 3-2. Rear Panel Connections And Rotating Drive Assembly 802 824-A / 802 825-A 2 3 4 1 14-Pin Control Cable - 10 ’ 2 Shielding Gas V alve Fitting Requires fitting with 5/8-18 right- hand threads. Connect customer- supplied gas hose.
OM-1500-4 Page 12 3-3. 14-Pin Plug Information Pin* Pin Information A 24 volts ac with respect to socket G. A J B Contact closure to A completes 24 volts ac contactor control circuit. A J B K I G Circuit common for 24 volts AC circuit. C L N H C +10 volts dc input from power source to wire feeder with respect to socket D.
OM-1500-4 Page 13 3-6. Installing And Threading Welding Wire Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / S-0627-A T ools Nee d e d : . For best wire feeding performance, be sure that the outlet cable has the proper size liner for the welding wire size being used.
OM-1500-4 Page 14 3-7. Setting Internal DIP Switches Position Settings And Results For DIP Switch S1 On = Current detect over- ride. For welding power sources that don ’ t provide current feedback through the 14-pin receptacle. Fac- tory set automatic run-in is inactive.
OM-1500-4 Page 15 T ools Needed: 1/4 in 3-8. Optional Equipment DIP Switch Settings 12 3 45 Or Or High Speed Motor Meters/Minute High Speed Motor Inches/Minute Standard Motor Meters/Minute Standard Motor Inches/Minute Digital Meter Functions 12 3 45 12 3 45 12 3 45 Ref.
OM-1500-4 Page 16 SECTION 4 – OPERA TION 4-1. Power Switch 1 Power Switch 1 802 827-A 4-2. Jog/Purge Pressing the Jog/Purge switch allows the op- erator to jog wire without energizing the weld power or gas valve circuit.
OM-1500-4 Page 17 4-3. T rigger Hold Switch 1 T rigger Hold Switch Trigger hold allows the operator to weld with- out holding the gun trigger . • T o use the trigger hold function, place the trigger hold switch in the On position.
OM-1500-4 Page 18 SECTION 5 – MAINTENANCE 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. Check 14-pin cord. Check gas hose and fittings.
OM-1500-4 Page 19 5-2. Diagnostics • Error Indications Error conditions are indicated by LED3 on PC 1 or on display if meter option is present. T o view LED3, turn Off unit, remove wrapper , and turn unit On. LED3 is most easily observed from the left side of the unit.
OM-1500-4 Page 20 Notes.
OM-1500-4 Page 21 SECTION 6 – ELECTRICAL DIAGRAM Figure 6-1. Circuit Diagram 202 246.
OM-1500-4 Page 22 SECTION 7 – P ARTS LIST 802 943 . Hardware is common and not available unless listed. Fig 7-2 21 Fig 7-3 4 1 2 6 14 15 16 17 18 19 20 5 7 8 9 10 11 12 11 10 13 3 Figure 7-1.
OM-1500-4 Page 23 Description Part No. Item No. Figure 7-1. Main Assembly Quantity 1 159 647 INSULA TOR, motor clamp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 159 646 CLAMP , motor base 1 .
OM-1500-4 Page 24 802 945 . Hardware is common and not available unless listed. 1 2 3 5 6 4 6 5 7 8 9 10 12 13 14 15 16 17 18 20 21 22 23 24 19 Figure 7-2. Control Box Description Part No. Dia. Mkgs. Item No. Figure 7-2. Control Box (Figure 7-1 Item 14) Quantity 1 200 555 WRAPPER, feeder 1 .
OM-1500-4 Page 25 Description Part No. Dia. Mkgs. Item No. Figure 7-2. Control Box (Figure 7-1 Item 14) (Continued) Quantity 22 202 237 P ANEL, front (base unit) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1500-4 Page 26 See T able 9-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 802 950 1 2 3 4 5 6 7 8 10 9 11 12 13 14 16 17 18 19 20 21 23 24 6 5 4 3 2 1 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 15 22 Figure 7-3.
OM-1500-4 Page 27 Description Part No. Dia. Mkgs. Item No. Figure 7-3. Drive Assembly , Wire (Figure 7-1 Item 23) (continued) Quantity 17 182 155 SPRING 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1500-4 Page 28 .023-.025 in. 0.6 mm 151 024 087 130 .030 in. 0.8 mm 151 025 053 695 .035 in. 0.9 mm 151 026 053 700 151 036 072 000 151 052 132 958 .045 in. 1.1/1.2 mm 151 027 053 697 151 037 053 701 151 053 132 957 151 070 083 489 .052 in. 1.3/1.4 mm 151 028 053 698 151 038 053 702 151 054 132 956 151 071 083 490 1/16 in.
OM-1500-4 Page 29 Notes.
OM-1500-4 Page 30 Notes.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y o ur distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor .
PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 W est S pencer St reet Applet on, WI 54914 USA International He adquarters –.
An important point after buying a device Miller Electric OM-1500-4 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric OM-1500-4 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric OM-1500-4 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric OM-1500-4 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric OM-1500-4 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric OM-1500-4, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric OM-1500-4.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric OM-1500-4. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric OM-1500-4 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
