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Miller Electric S-75D manual

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Table of contents for the manual

  • Page 1

    Visit our website at www.MillerWelds.com S-75S, S-75D Processes Description MIG (GMA W) W elding Flux Cored (FCA W ) Welding (Gas- And Self-Shielded) Wire Feeder OM-223 605A May 2005[...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-223 605 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 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 me[...]

  • Page 6

    OM-223 605 Page 2 Arc rays from the w elding 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 an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching[...]

  • Page 7

    OM-223 605 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.[...]

  • Page 8

    OM-223 605 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A W[...]

  • Page 9

    OM-223 605 Pa ge 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les ut ilisés Sy m bole graphique d’av ertiss ement ! Attention ! Cette pro- cédur e c omport e d es risques poss ib[...]

  • Page 10

    OM-223 605 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la pe[...]

  • Page 11

    OM-223 605 Pa ge 7 2-3 . Dangers s upplé mentaire s e n rela t i on a v ec l’installa tion, l e fonctionneme nt e t la maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surchar[...]

  • Page 12

    OM-223 605 Page 8 2-5. Princi pales n ormes de sécu rité Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W el[...]

  • Page 13

    OM-223 605 Page 9 SECTION 3 − DEFINITIONS 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 56 + 2.3 S-178 936 A. W arning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. W elding wire and drive parts are at welding voltage during operation − keep hands and metal objects clear . 1 Electric s[...]

  • Page 14

    OM-223 605 Page 10 3-2. Symbols And Definitions Some symbols are found only on CE products. Note A Amperes V V olts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz Program Wire Feed Jog Output Trigger Line Connection Set Up Sequence Trigger Hold On Trigger Hold Of f Purge Press T o Set Start Crater T ime Preflow Time Postflow Time[...]

  • Page 15

    OM-223 605 Page 1 1 SECTION 4 − INTRODUCTION 4-1. Specifications T ype of Input Power W elding Power Source T ype W elding Circuit Rating IP Rating Overall Dimensions Maximum Spool W eight Wire Feed Speed Range Wire Diameter Range W eight 24 V olts ac Single-Phase 10 Amperes 50/60 Hertz Constant V oltage (CV) DC With 14-Pin, that Provides V oltag[...]

  • Page 16

    OM-223 605 Page 12 5-2. Rear Panel Connections And Rotating Drive Assembly Ref. 804 183-A / 804 184-A 2 4 1 14-Pin Control Cable - 10 ft (3.0 m) 2 Shielding Gas V alve Fitting Connect customer-supplied gas hose with 5/8-18 right-hand threads. . Shielding gas pressure not to exceed 90 PSI (620 kPa). 3 Weld Cable 4 W eld Cable Screw - Screw Size (.37[...]

  • Page 17

    OM-223 605 Page 13 5-3. 14-Pin Plug PLG12 Information Pin* Pin Information A 24 volts ac with respect to socket G. A J K B Contact closure to A completes 24 volts ac contactor control circuit. A J B K I L G Circuit common for 24 volts ac circuit. C L N H D M G C +10 volts dc input from power source to wire feeder with respect to socket D. D M G E F[...]

  • Page 18

    OM-223 605 Page 14 5-7. Installing PD Continuous Wire Guides Ref. 804 192 / 804 188-A . PD Continuos Wire Guides: Should be used with .068/.072 in (1.8 mm) and smaller diameter wire for opti- mal performance. Should be used with PD drive rolls and cannot be used with non-PD (old-style) drive rolls. . 70 series wire guides are not compatible with 75[...]

  • Page 19

    OM-223 605 Page 15 5-8. Installing Non-PD (Old Style) Wire Guides Ref. 804 192 / 804 188-A Installing wire guides with non- PD (old-style) drive rolls. . Non-PD (old-style) wire guides and drive rolls should be used with 5/64 in (2.0 mm) and larger diameter wire. 1 Pressure Assembly Door 2 PD Inlet Guide 3 Intermediate Guide 4 Guide Holder 5 Exit G[...]

  • Page 20

    OM-223 605 Page 16 5-9. Installing Welding Gun 804 189-A 1 Power Clamp Knob 2 Gun Locking T ab 3 Power Pin Groove 4 Gun Connection End Installing gun with Accu-Mate connection. Loosen power clamp knob to allow power pin of gun to clear the gun locking tab. When installing gun, the liner should extend into the PD continu- ous guide (or exit guide if[...]

  • Page 21

    OM-223 605 Page 17 5-10. Installing W elding Wire And Adjusting Pressure Drive Setting Ref. 804 190-A T ools Needed: 1 Drive Roll Pressure Adjustment Lever 2 Notch In Lever (Indicates Pressure Settings) Pressure drive settings range from 1 to 9 with 9 being the maximum setting. . For aluminum (soft wire) set pressure drive setting at 4 or below . .[...]

  • Page 22

    OM-223 605 Page 18 5-1 1. Setting Internal DIP Switches Position Settings And Results For DIP Switch S1 On PC1 Run-In feature is not avail- able. X - Means switch may be in either position. Run-In feature is available. X - Means switch may be in either position. . If 14 pin power cable from pow- er source does not provide volt- ag e and current fee[...]

  • Page 23

    OM-223 605 Page 19 T ools Needed: 1/4 in 5-12. Equipment DIP Switch Settings (For Models With Meters Only) 12 3 45 Factory Default Inches/Minute Digital Meter DIP Switch Setting Ref. 802 946 Remove wrapper . Install wrapper when finished. 12 3 45 Factory Default Meters/Minute[...]

  • Page 24

    OM-223 605 Page 20 SECTION 6 − OPERA TION 6-1. Power Switch 1 Power Switch 804 182-A 1 6-2. Jog/Purge And T rigger Hold 1 802 828-A 3 1 Jog/Purge Push Button Pressing the Jog/Purge switch al- lows the operator to jog wire without energizing the weld power or gas valve circuit. • Jog speed can be adjusted with the Wire Speed control when the uni[...]

  • Page 25

    OM-223 605 Page 21 6-3. V oltage Control And Digital Meters (For Models With Meters Only) 3 804 182-A 1 2 1 V oltmeter The voltmeter displays actual or preset voltage from the welding power source through the 14 − pin control cable. 2 Wire Speed Meter Th e wire speed meter is factory set to display inches per minute. If dis- play of meters per mi[...]

  • Page 26

    OM-223 605 Page 22 7-2. Diagnostics • Error Indications Error conditions are indicated by LED3 on PC 1 or on display (on models with meters). T o view LED3, turn Off unit, remove wrapper , an d turn unit On. LED3 is most easily observed from the left side of the unit. The LED blinks in a 2.5 second cycle. The number of blinks in this period indic[...]

  • Page 27

    OM-223 605 Page 23 7-3. T roubleshooting Y Disconnect power before troubleshooting T rouble Remedy Wire feeds, shielding gas flows, but electrode wire is not energized. Check cable connections. Check cables for continuity , and repair or replace cables if necessary (see Section 5-2). Wire feeder is on, display does not light up, motor does not run,[...]

  • Page 28

    OM-223 605 Page 24 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram 202 246-B[...]

  • Page 29

    OM-223 605 Page 25 Notes[...]

  • Page 30

    OM-223 605 Page 26 SECTION 9 − P ARTS LIST 804 185-A . Hardware is common and not available unless listed. Fig 9-2 Fig 9-3, 9-4 21 20 19 18 5 17 16 15 14 13 10 11 12 11 10 9 8 7 6 4 3 2 1 22 Figure 9-1. Main Assembly[...]

  • Page 31

    OM-223 605 Page 27 Item No. Item No. Part No. Description Quantity Figure 9-1. Main Assembly Part No. Description Quantity 1 159 647 Insulator , Motor Clamp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 159 646 Clamp, Motor Base 1 . . . . . . . . . . . . . . . . . . .[...]

  • Page 32

    OM-223 605 Page 28 802 945-D . Hardware is common and not available unless listed. 2 5 6 7 8 9 8 7 10 11 12 13 14 15 16 17 18 19 20 23 24 25 26 27 22 28 4 21 3 1 29 Figure 9-2. Control Box Item No. S-75S S-75D Figure 9-2. Control Box (Figure 9-1 Item 21) Diagram marking Part No. Description Quantity Model 1 200 555 Wrapper , Feeder 1 1 . . . . . . [...]

  • Page 33

    OM-223 605 Page 29 Item No. Diagram marking Part No. Description Quantity Model S-75S S-75D Figure 9-2. Control Box (Figure 9-1 Item 21) 21 213 134 Knob, Encoder 1.670 Dia X .250 Id Push On W/Spring 0 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1 19 951 Blank, Snap-in Nyl .437 Mtg Hole Black 1 0 . . . . . . . . . . . . . . [...]

  • Page 34

    OM-223 605 Page 30 See T able 9-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 804 186-A 4 5 6 7 8 3 2 1 9 10 2 11 12 13 14 15 16 17 18 19 20 21 22 Figure 9-3. Drive Assembly , Wire Item No. Item No. Part No. Description Quantity Figure 9-3. Drive Assembly With Motor (Figure 9-1 Item 4) Part No. Descrip[...]

  • Page 35

    OM-223 605 Page 31 . Hardware is common and not available unless listed. 804 191-A 1 2 3 4 5 6 Figure 9-4. Drive Assembly With Motor Item No. Diagram marking Part No. Description Quantity Model S-75S S-75D Figure 9-4. Drive Assembly , Wire (Figure 9-1 Item 4) 1 079 626 Screw, 010 − 32x .87 Fil Hd − Phl Stl Pld Lkg Patch 4 4 . . . . . . . . . . [...]

  • Page 36

    OM-223 605 Page 32 Wire Size PD for Hard Wire (1 kit or 4 rolls & 1 guide required) PD for Aluminum (1 kit or 4 rolls & 1 guide required) Guides for Old Style Drive Rolls (1 each required) Standard Drive Rolls ( 4 required) Fraction Metric PD Kit Roll Guide Roll Inlet Intermediate Exit V Groove U Groove VK Groove UC Groove .023 − .025 in.[...]

  • Page 37

    Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.weldin g .or g Star t Y our Pr ofessional W eldin g Career Now![...]

  • Page 38

    Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MA TERIAL THICKNESS REFERENCE CHART[...]

  • Page 39

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

  • Page 40

    PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05 Miller Elect ric Mf g. Co. An Illinois T ool Wo rks Co mpany 1635 W es t Spencer St reet Applet on, WI 5 4914 USA International He adquarters − US A USA Phone: 920-735-4505 Aut o-Att ended USA & Canada F A X: 920-735-4134 Int ernational F AX : 9 20-735-4125 European Headqua rters − United[...]