Related Manuals for Miller Electric 75
Summary of Contents for Miller Electric 75
- Page 1 OM-228 956B 2006−08 Processes MIG (GMAW) Welding Description Wire Feeder Axcess AlumaFeed 75 Visit our website at File: Advanced Manufacturing Systems www.MillerWelds.com...
- Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. 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 specification sheets.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... 1-2. -
Page 5: Section 1 − Safety Precautions - Read Before Using
DC 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 work alone! D Disconnect input power or stop engine before installing or servicing this equipment. - Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
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: Principal Safety Standards
1-5. Principal Safety Standards Safety in Welding, 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 Welding and Cut- ting of Containers and Piping, American Welding Society Standard F4.1 from Global... -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. - Page 10 LES RAYONS D’ARC peuvent entraî- ner des brûlures aux yeux et à la peau. 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.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et 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 surcharger l’installation électrique −... -
Page 12: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, 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 for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). -
Page 13: Section 3 − Introduction
SECTION 3 − INTRODUCTION 3-1. Specifications Type of Input Welding Power Wire Feed Speed Range Power Source Type 40 Volts DC Axcess Series Standard: 40 To 1400 ipm (1.0 10 Amperes SECTION 4 − INSTALLATION 4-1. Selecting A Location Movement Location Y Special installation may be required where gasoline or volatile liquids are present −... -
Page 14: Connection Diagram
4-2. Connection Diagram OM-228 956 Page 10 Welding Power Source Wire Feeder Gas Cylinder Gas Hose Network Feeder Cable Negative (−) Weld Cable Workpiece Voltage Sensing Lead (Optional) Positive (+) voltage sensing lead is contained in the motor cable. Positive (+) Weld Cable Ref. -
Page 15: Rear Panel Connections And Rotating Drive Assembly
4-3. Rear Panel Connections And Rotating Drive Assembly Tools Needed: 9/16, 5/8 in 3/16 in 350 Amps and above weld connection 0 to 350 Amps weld connection 9-Pin Network Receptacle Shielding Gas Valve Fitting Requires fitting with 5/8-18 right- hand threads. Connect customer- supplied gas hose. -
Page 16: 9-Pin Network Receptacle Information
4-4. 9-Pin Network Receptacle Information Capacitor C1 to ground Shield Volt sense Can low Can high +24 volts dc common + 24 volts dc Motor voltage −40 volts Motor voltage +40 volts 4-5. Installing Drive Rolls OM-228 956 Page 12 Pin Information Pressure Assembly Door Drive Roll... -
Page 17: Installing Pd Continuous Wire Guides
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 series wire feeders. Pressure Assembly Door PD Inlet Guide PD Wire Guide (Hard Wire) PD Wire Guide (Two Pieces... -
Page 18: Installing Non-Pd (Old Style) Wire Guides
4-7. Installing Non-PD (Old Style) Wire Guides OM-228 956 Page 14 Installing wire guides with non- PD (old-style) drive rolls Open pressure assembly door. Lift up drive roll swing arms. Install PD inlet guide. Remove screw securing intermedi- ate guide holder. (Guide holder is located between the lower front and rear drive roll carriers.) Rotate guide holder 180 degrees... -
Page 19: Installing Welding Gun
4-8. Installing Welding Gun Installing gun with Accu-Mate connection Installing gun without Accu-Mate connection Power Clamp Knob Gun Locking Tab Power Pin Groove 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. -
Page 20: Installing Welding Wire And Adjusting Pressure Drive Setting
4-9. Installing Welding Wire And Adjusting Pressure Drive Setting Install wire spool. Adjust tension nut so wire is taut when wire feed stops. Drive Rolls Pressure assembly door not shown. No Wire Slip Wire Slips NONCONDUCTIVE NONCONDUCTIVE SURFACE SURFACE Drive Roll Pressure Adjustment Lever Notch In Lever (Indicates Pressure Settings) Pressure drive settings range from 1 to 8 with... -
Page 21: Feeder Display At Power Up
4-10. Feeder Display At Power Up Program Volts Process Wire Type Gas Type Process Set Up Adjust Power Source Upper Display Axcess Axcs 4-11. Dual Schedule Switch Options DSS-9M Time Arc Adjust Amps Arc Ctl Sequence Trigger Control Trigger Hold Feeder Set Up Lower Display Voltage Range... -
Page 22: Section 5 − Operation
SECTION 5 − OPERATION 5-1. Operational Terms The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder: General Terms: Arc Adjust Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases the actual arc length. -
Page 23: Power Switch
General Terms: Crater Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends. Postflow Setting a time value for gas flow after arc end. Feeder Set Up Allow selection of Sequence and trigger functions. Auto Thread Method of jogging wire without holding jog or trigger switch. -
Page 24: Front Panel Controls
5-3. Front Panel Controls Section Program Process Wire Type Gas Type Process Set Up Section OM-228 956 Page 20 Volts Time Arc Adjust Amps Arc Ctl Sequence Trigger Control Trigger Hold Adjust Feeder Set Up Section Section Section Section... -
Page 25: Program Push Button
5-4. Program Push Button 5-5. Upper Display Upper Display The upper display shows voltage or arc length. The unit displays both preset voltage or arc length and actual voltage. When welding, actual arc voltage is displayed. Upper Display Push Button Press the button to illuminate the LED and allow changing information in the display. -
Page 26: Lower Display
5-6. Lower Display Lower Display The lower display shows WFS (wire feed speed), AMPS (amperage), ARC CTL (arc control), or Time. The feeder displays only preset wire speed at idle (not welding). While welding, the average amperage is displayed. The lower display shows welding sequence time when the Time LED is illuminated. -
Page 27: Feeder Set Up Push Button
5-7. Feeder Set Up Push Button Sequence Trigger Control Trigger Hold Feeder Set Up Feeder Set Up Push Button Feeder Set Up Push Button LED Press button to choose sequence, trigger control, or trigger hold. Sequence LED Trigger Control LED Trigger Hold LED Lock LED (Access Allowed Only By Using An Optional PDA With File... -
Page 28: Process Set Up Push Button
Alloy Type E70, E100, E120 90% Argon/10% CO 85% Argon/15% CO 75% Argon/25% CO 95% Argon/5% CO 95% Argon /5% O 98% Argon/2% O 308, 309, 312, 316 98% Argon, 2% O... -
Page 29: Jog/Purge
5-10. Jog/Purge Pressing the Jog/Purge switch allows the operator to jog wire without energizing the weld power or gas valve circuit. 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 operation for a maximum of 30 seconds. -
Page 30: Reset Mode
Program 1 Pulse .035 Mild Steel 90% Argon, 10% CO Program 2 .035 Mild Steel 75% Argon, 25% CO Program 3 Accu-pulse .035 Mild Steel 90% Argon, 10% O2 Program 4 Pulse .045 Mild Steel... -
Page 31: Section 6 − Setting Sequence Parameters
SECTION 6 − SETTING SEQUENCE PARAMETERS 6-1. Sequence Parameters In A Program Sequence 1. Preflow 2. Postflow 3. Start 4. Crater X = Setting available. Start Time Preflow Time Start Preflow Trigger Pressed Parameters Volts/Trim Seconds Off-5.0 Off-5.0 10.0-44.0/ 40-1400/ Off-5.0 0-99 0-99... -
Page 32: Section 7 − Maintenance
SECTION 7 − MAINTENANCE 7-1. Routine Maintenance n = Check Z = Change * To be done by Factory Authorized Service Agent Every Every l Unreadable Labels ~ Weld Terminals Months n 14-Pin Cord n Gas Hose And Fittings Every Months ~ Inside Of Unit ~ Drive Rolls... -
Page 33: Diagnostics
7-2. Diagnostics The following error messages are shown on the upper and lower displays to indicate specific errors. Explanations are in the text below: SENS TACH Indicates a voltage Indicates a sense error. tachometer error. FLOW COOL Indicates a gas Indicates a coolant flow error. - Page 34 7-2. Diagnostics (Continued) TEMP LINE Indicates a Indicates a line temperature error. error. MOTR WELD WAIT Indicates a memory Indicates a weld CRC motor error. cycle wait error. ERR TEMP The temperature error indicates welding power source overheated shutdown. The error may be cleared by allowing unit to cool down, and pressing the Jog/Purge button.
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Page 35: Troubleshooting
7-2. Diagnostics (Continued) OVER DONE AVER Indicates RMD Indicates an over demo is done. average current error. RMD DONE The RMD done message indicates the RMD demo is completed. Pressing Jog/Purge button will change the screen to CYCL PWR on the display. Turn unit power off and back on again. -
Page 36: Section 8 − Electrical Diagram
SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram OM-228 956 Page 32... - Page 37 211 005-D OM-228 956 Page 33...
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Page 38: Section 9 − Parts List
SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 4 − Fig 9-3, 9-4 21 − Fig 9-2 804 588-A Figure 9-1. Main Assembly OM-228 956 Page 34... - Page 39 Item Part ....159 647 ....159 646 .
- Page 40 Item Dia. Part Mkgs....134 464 ....+212 781 .
- Page 41 Item Dia. Part Mkgs....228 270 ....210 998 .
- Page 42 ........Washer, Wave .500 Idx0.750 Odx.015t Stl Lbs Ring, Rtng Ext .500 Shaft X .035 Thk Screw, 250−20x1.75 Hexwhd.61D Gr5 Pld Screw, 375−16x2.00 Hexwhd.81D Pld Washer, Flat .281 Idx0.625 Odx.065t Stl Pld Ansi.250 Screw, 250−20x .50 Button Hd−Soc Stl Pld...
- Page 43 Hardware is common and not available unless listed. Item Dia. Part Mkgs....220 012 ....Figure 9-3 .
- Page 44 OM-228 956 Page 40...
- Page 45 Notes...
- Page 46 Notes...
- Page 47 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.
- Page 48 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. 2006 Miller Electric Mfg. Co. 2006−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...