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OM-1500-10 Page 26

SECTION 9 − PARTS LIST

802943-B

.

Hardware is common and
not available unless listed.

Fig 9-2

21

Fig 9-3

4

1

2

6

14

15

16

17

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20

5

7

8

9

10

11

12

11

10

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9

22

Figure 9-1. Main Assembly

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Summary of Contents for 300616

Page 1: ... Description MIG GMAW Welding Flux Cored FCAW Welding Gas And Self Shielded Wire Feeder OM 1500 10 207748AC 2017 06 File MIG GMAW CE For product information Owner s Manual translations and more visit www MillerWelds com ams ...

Page 2: ...ontinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operati...

Page 3: ...tions 9 3 2 Miscellaneous Symbols And Definitions 11 SECTION 4 SPECIFICATIONS 12 4 1 Serial Number And Rating Label Location 12 4 2 Unit Specifications 12 4 3 Wire Type Size And Feed Speed Capability Table 12 4 4 Environmental Specifications 12 SECTION 5 INSTALLATION 14 5 1 Selecting A Location 14 5 2 Rear Panel Connections And Rotating Drive Assembly 15 5 3 14 Pin Plug PLG12 Information 16 5 4 In...

Page 4: ... 300616002 S 74D FEEDER 300617 S 74D FEEDER W HIGH SPEED MOTOR 300617001 S 74D FEEDER W CE EURO 300617003 Council Directives 2014 35 EU Low voltage 2014 30 EU Electromagnetic compatibility 2011 65 EU Restriction of the use of certain hazardous substances in electrical and electronic equipment Standards IEC 60974 5 2013 Arc welding equipment Part 5 Wire feeders IEC 60974 10 2014 Arc welding equipme...

Page 5: ...kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not wor...

Page 6: ...pared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere can contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D Do not use welder to thaw frozen pipes D...

Page 7: ...TS can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all labels an...

Page 8: ...NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 ther...

Page 9: ...nement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou s il y a un risque élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol Dans ces conditions utiliser les équipements suivants dans l ordre indiqué 1 un poste à souder DC à tension constante à fil 2 u...

Page 10: ...udes et des équipements chauds peut provoquer des incen dies et des brûlures Le contact accidentel de l électrode avec des objets métalliques peut provoquer des étincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage vérifier et s assurer que l endroit ne présente pas de danger D Déplacer toutes les substances inflammables à une distance de 10 7 m de l arc de souda...

Page 11: ... capacité suffisante pour lever 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 Tenir l équipement câbles et cordons à distance des véhicules mobiles lors de toute opération en hauteur D Suivre les consignes du Manuel des applications pour l équation de levage NIOSH révisée Publ...

Page 12: ...om bustibles American Welding Society Standard AWS A6 0 from Global EngineeringDocuments phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501...

Page 13: ...cycling office or your local distributor for further information Safe37 2017 04 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves Safe2 2017 04 Protect yourself from electric shock by insulating yourself from work and ground Safe3 2017 04 Disconnect input plug or power before working on machine Safe5 2017 04 Keep your head out of the fumes Safe6 201...

Page 14: ... injure fingers Safe32 2012 05 Welding wire and drive parts are at welding voltage during operation keep hands and metal objects away Safe33 2017 04 EnvironmentalProtection Use Period China Safe123 2016 06 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection Safe66 2012 06 Become trained and read the in...

Page 15: ...ent Purge By Gas Constant Voltage I2 Rated Welding Current Program Variable Inductance Preflow Time Line Connection U2 Conventional Load Voltage Wire Feed Cold Jog Inch Towards Workpiece Circuit Breaker Trigger Hold On Sequence Gas Type Trigger Control Three Phase U1 Primary Voltage Output X Duty Cycle Input Constant Current Trigger Hold Off I1 Primary Current Wire Type Arc Control Single Phase Re...

Page 16: ...d Speed Range Rated Speed Range per IEC 60974 5 Standard Speed All 023 To 5 64 in 0 6 To 2 mm 50 To 780 ipm 1 3 To 19 8 mpm 55 To 770 ipm 1 4 To 19 6 mpm Low Speed All 5 64 in To 1 8 in 2 0 To 3 2 mm 19 To 300 ipm 0 4 To 7 6 mpm 55 To 300 ipm 1 4 To 7 6 mpm High Speed All 023 To 5 64 in 0 6 To 2 mm 90 To 1440 ipm 2 3 To 36 6 mpm 92 To 1435 ipm 2 3 To 36 5 mpm 4 4 Environmental Specifications A IP ...

Page 17: ... T 11364 规 This table is prepared in accordance with China SJ T 11364 O 表2该质5该部 7 8质9 量85 GB T26572规限量要 Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China GB T 26572 X 表2该质AC5该部 DE8质9 量超F GB T26572规限量要 Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the...

Page 18: ...hits cylinder Wire feeder shown is repre sentative only and may not reflect actual unit 1 Wire Feeder 2 Rubber Feet Choose slot that allows all rubber feet to sit securely on top of welding power source 3 Wire Spool Reel 4 Gas Cylinder w Hose And Regulator Customer Supplied Shielding gas pressure not to exceed 100 psi 689 kPa 5 Welding Power Source 6 Running Gear 1 3 5 4 2 6 ...

Page 19: ...nect customer supplied gas hose with 5 8 18 right hand threads Shielding gas pressure not to exceed 100 PSI 689 kPa 3 Weld Cable Terminal 4 Weld Cable 5 Drive Assembly 6 Drive Assembly Rotation Knob 7 Rating Label Location To rotate the drive assembly loos en drive assembly rotation knob rotate drive assembly and tighten knob 9 16 5 8 in Tools Needed 3 16 in 5 6 1 7 3 4 ...

Page 20: ...1 Gun Locking Tab 2 Power Clamp Knob 3 Gun Connection End 4 Power Pin Groove Installing gun with Accu Mate connection Loosen power clamp knob to allow power pin of gun to clear the gun locking tab Push power pin into power clamp as far as possible to align the groove in the power pin of the gun with the gun locking tab Secure gun by tightening power clamp knob Installing gun without Accu Mate conn...

Page 21: ...duce drive roll pressure on the rear roll to half that of the front rolls To adjust drive roll pressure hold nozzle about 2 in 51 mm from nonconductive surface and press gun trigger to feed wire against surface Tighten knob so wire does not slip Do not overtighten If con tact tip is completely blocked wire should slip at the feeder see pressure adjust ment above Cut wire off Close cover NONCONDUCT...

Page 22: ...ptacle Pins F H are not present in 14 pin receptacle on machines that don t provide current feed back Install wrapper when finished Ref 805426 B Tools Needed 1 4 in S1 1 And S1 2 S1 1 And S1 2 Current Detect Override ON Current Detect Override OFF Factory Default On Run In speed is approximately 1 2 weld wire feed speed Off Run In speed is set using potentiometer P1 located on Motor Board PC1 S1 1...

Page 23: ...For Models With Meters Only 1 2 3 4 5 Or Or High Speed Motor Meters Minute High Speed Motor Inches Minute Standard Motor Meters Minute Standard Motor Inches Minute Digital Meter Functions 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 Ref 802946 B Remove wrapper Install wrapper when finished ...

Page 24: ...e welding arc does not initiate in 3 seconds after the gun trigger is activated the unit will perform a jog operation for a maximum of two minutes If the gun trigger is still activated after two minutes the jog operation is terminated to prevent complete despooling of the wire as in the case of a dam aged gun Jog speed can be adjusted with the Wire Speed control when the unit is jogging wire If eq...

Page 25: ...gain 1 802828 B 6 4 Voltage Control And Digital Meters For Models With Meters Only 3 802827 B 1 2 1 Voltmeter The voltmeter displays actual or preset voltage from the welding power source through the 14 pin control cable 2 Wire Speed Meter The wire speed meter is factory set to display inches per minute If dis play of meters per minute is de sired see Section 5 7 3 Voltage Control Use control to a...

Page 26: ...ntaining 3 Months Replace unreadable labels Clean and tighten weld terminals Repair or replace cracked weld cable Check 14 pin cord Check gas hose and fittings Check gun cable Replace cracked parts 6 Months Blow out or vacuum inside During heavy service clean monthly Or Clean drive rolls Notes ...

Page 27: ...ger held for more than two minutes with out striking an arc providing current over ride is not enabled or if the user holds the trigger past the postflow phase in a timed weld This error also occurs if the trigger is held when the feeder is powered up The er ror may be cleared by releasing the trigger The tach error occurs 2 seconds after the loss of tachometer feedback The user may continue to we...

Page 28: ...cally during welding Check gun trigger connection See gun Owner s Manual Check gun trigger See gun Owner s Manual Readjust hub tension and drive roll pressure see Section 5 5 Change to correct size drive roll see 5 5 Clean or replace dirty or worn drive roll Incorrect size or worn wire guides Replace contact tip or liner See gun Owner s Manual Remove weld spatter or foreign matter from around nozz...

Page 29: ...OM 1500 10 Page 25 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram 202 246 C ...

Page 30: ... 1500 10 Page 26 SECTION 9 PARTS LIST 802943 B Hardware is common and not available unless listed Fig 9 2 21 Fig 9 3 4 1 2 6 14 15 16 17 18 19 20 5 7 8 9 10 11 12 11 10 13 3 9 22 Figure 9 1 Main Assembly ...

Page 31: ... X 125 Thk 2 11 058628 Washer Brake Stl 2 12 058428 Hub Spool 1 13 248974 Tubing Stl 875 OD x 12 Ga Wall x 562 1 14 135205 Nut Stl Slflkg Hex Reg 625 11 W Nylon Insert 1 15 200556 Support Spool 1 16 201781 Knob W Extension Clamp 1 17 156243 Clamp Motor Top 1 18 145639 Strip Buna N Compressed Sheet 062 X 4 000 X 4 000 1 19 200552 Base 1 20 134306 Foot Rubber 1 250 Dia X 1 375 High No 10 Screw 4 21 ...

Page 32: ...ushing Snap In Nyl 937 Id X 1 125 Mtg Hole 1 1 240644 Cable Power Consisting Of 1 1 7 163519 Cable Port 11 5 Ft 3 5 m 8 139041 Strain Relief 1 1 9 079739 Conn Circ Cpc Clamp Str Rlf 1 1 10 PLG12 141162 Housing Plug Pins Service Kit 1 1 PLG3 115092 Housing Plug Skts Service Kit 1 1 11 200554 Enclosure Motor 1 1 12 605227 Nut 750 14 Knurled1 68Dia 41H Nyl 1 1 13 GS1 228035 Valve 34VDC 1Way 750 14 Th...

Page 33: ...g Skts Service Kit 1 1 PLG1 202592 Housing Plug Pins Skts Service Kit 1 1 PLG4 136810 Housing Plug Pins Skts Service Kit 1 1 PLG10 130203 Housing Plug Skts Service Kit 1 1 27 R1 208399 Potentiometer Cp Std Slot 1t 2 W 10K Linear W Frict Tabs 1 0 27 R1 224597 Potentiometer Cermet Std Flat 3 75t 2 W 10K Linear 0 1 28 R70 224597 Potentiometer Cermet Std Flat 3 75t 2 W 10K Linear 0 1 PLG7 27 115091 Ho...

Page 34: ...62 Spacer Carrier Drive Roll 4 4 4 149486 Pin Rotation Arm Rocker 2 2 5 132750 Arm Pressure 2 2 6 150520 Spacer Flat Stl 257 Id X 619 Od X 105 2 2 7 133493 Ring Retaining Ext 250 Shaft X 025Thk 1 1 8 133350 Pin Hinge 1 1 9 M1 201230 Motor Gear 1 8Hp 24VDC Standard Speed 1 1 9 M1 201231 Motor Gear 1 8Hp 24VDC High Speed Optional On S 74D 0 1 153491 Kit Brush Replacement Consisting Of 1 1 153492 Cap...

Page 35: ...1 23 167387 Spacer Locating 2 2 24 168825 Drive Pinion 1 2 25 133308 Ring Retaining Ext 375 Shaft X 025 Thk 1 1 26 134834 Hose Sae 187 Id X 410 Od Order By Ft 2 Ft 0 6 m 27 244579 Adapter Assy Gun Feeder Lh Accu Mate Consisting Of 1 1 28 601966 Screw Cap Stl Hexhd 375 16 X 1 250 1 1 29 149959 Fitting Brs Barbed M 3 16Tbg X 312 24 1 1 30 167788 Nut 375 16 56Hex 34H Stl Pld Sem Cone Wshr 88D 1 1 31 ...

Page 36: ...265257 068 072 in 1 8 mm 151056 5 64 in 2 0 mm 151040 151057 151073 3 32 in 2 4 mm 151041 151058 151074 7 64 in 2 8 mm 151042 151059 151075 1 8 in 3 2 mm 151043 151060 151076 Accommodates 045 and 047 3 64 in wire Requires a low speed wire feeder Wire Guides Nylon Wire Guides for Feeding Aluminum Wire Wire Sizes Inlet Guide Intermediate Guide Wire Size Inlet Guide Intermediate Guide 023 to 040 in 0...

Page 37: ...Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now ...

Page 38: ...Notes ...

Page 39: ...G Guns Subarc SAW Torches and External Cladding Heads Remote Controls and RFCS RJ45 Replacement Parts No labor Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on ...

Page 40: ...h your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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