Miller Electric DS-75D16 Swingarc Owner's Manual
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Miller Electric DS-75D16 Swingarc Owner's Manual

Miller Electric DS-75D16 Swingarc Owner's Manual

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DS-75S/D Swingarc
DS-75S12, DS-75S16, DS-75D12, and DS-75D16
OM-230 300A
2006−09
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas-and Self-Shielding)
Submerged (SAW) Welding
Description
Wire Feeder
(Use with CV Power Sources)
File: MIG (GMAW)

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Summary of Contents for Miller Electric DS-75D16 Swingarc

  • Page 1 DS-75S/D Swingarc Visit our website at www.MillerWelds.com DS-75S12, DS-75S16, DS-75D12, and DS-75D16 OM-230 300A 2006−09 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding (Gas-and Self-Shielding) Submerged (SAW) Welding Description Wire Feeder (Use with CV Power Sources) File: MIG (GMAW)
  • 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.

  • 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.

  • 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.

  • 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 Power Source Type 24 Volts AC Constant Voltage (CV) Single-Phase DC With 14-Pin that provides 10 Amperes voltage and current feedback 50/60 Hertz Maximum Height With 4 ft (1.2 m) Post Vertical Lift Of Boom NOTE If feeder is used with a welding power source that does not provide voltage and...

  • Page 14: Installing Control Box And Adjusting Tilt

    4-2. Installing Control Box And Adjusting Tilt Tools Needed: 3/8 in 4-3. Installing Boom And Reel Support Tools Needed: 3/8, 3/4 in OM-230 300 Page 10 Weld Control Bracket Screw Bracket and screws are installed onto bottom of control at factory. Swivel Loosen screws.

  • Page 15: Installing Wire Guide Extension

    4-4. Installing Wire Guide Extension Tools Needed: 3/8 in 4-5. Installing Guard This illustration shows the mounting screws in place for a standard speed motor. The remaining holes are used for low speed motors. Wire Guide Fitting Bolt Monocoil Liner Wire Guide Extension Tighten bolt to secure liner in wire guide fitting.

  • Page 16: Equipment Connection Diagram

    4-6. Equipment Connection Diagram OM-230 300 Page 12 Y Turn Off wire feeder and welding power source. Stop engine on welding generator. Y Use only with CC/CV DC Power Sources. Constant Current (CC) or Constant Voltage (CV) Welding Power Supply Remote 14 Connection Ground Cable To Workpiece Weld Cable To Feeder...

  • Page 17: Control Box Connections

    4-7. Control Box Connections 4-8. 14-Pin Plug Information Pin* *The remaining pins are not used. Pin Information 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. +10 volts dc input from power source to wire feeder with respect to socket D.

  • Page 18: Removing Safety Collar And Adjusting Boom

    4-9. Removing Safety Collar And Adjusting Boom Tools Needed: 1-1/8 in 4-10. Gun Recommendation Table Process GMAW − Hard or Cored Wires FCAW − Self-Shielding Wires 4-11. Wire Type, Size, And Feed Speed Capability Table Motor Speed Wire Type Standard OM-230 300 Page 14 Increasing Spring Decreasing Spring...

  • Page 19: Installing Drive Rolls

    4-12. Installing Drive Rolls Notes Drive Roll Carrier Ejector Button Drive Roll Pressure Door Assembly Installation Open pressure door assembly. Lift drive roll swing arm. Align drive roll slots with three lobes on drive roll carrier. Insert drive roll onto carrier. Drive roll will snap into place.

  • Page 20: Installing Pd Continuous Wire Guides

    4-13. Installing PD Continuous Wire Guides PD Continuous Wire Guides: Should be used with .068/.072 in (1.8 mm) and smaller diameter wire for optimal 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 compat- ible with 75 series wire feeders.

  • Page 21: Installing Non-Pd (Old Style) Wire Guides

    4-14. Installing Non-PD (Old Style) Wire Guides 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. PD Inlet Guide Intermediate Guide Guide Holder Exit Guide Set Screw...

  • Page 22: Installing Welding Gun

    4-15. Installing Welding Gun Installing gun with Accu-Mate connection Gun Locking Tab Power Clamp Knob Power Pin Groove Gun Connection End Installing gun with Accu-Mate connec- tion Loosen power clamp knob to allow power pin of gun to clear the gun locking tab. When installing gun, the liner should extend OM-230 300 Page 18 into the PD continuous guide (or exit guide...

  • Page 23: Installing Welding Wire And Adjusting Pressure Drive Setting

    4-16. Installing Welding Wire And Adjusting Pressure Drive Setting Install wire spool. Ad- just tension nut so wire is taut when wire feed stops. Drive Rolls End Of Liner Back Of Gun NONCONDUCTIVE SURFACE No Wire Slip Drive Roll Pressure Adjustment Lever Notch In Lever (Indicates Pressure Settings) Pressure drive settings range from 1 to 8 with...

  • Page 24: Setting Internal Dip Switches On Motor Boards

    4-17. Setting Internal DIP Switches On Motor Boards Right Side Motor Control Board PC1 Position Settings And Results For DIP Switch S1 On PC1, 101 Run-In Enabled (Factory Default) S1-1 Run-In feature is not avail- Run-In feature is available. X - Means switch may be in either able.

  • Page 25: Equipment Dip Switch Settings (For Models With Meters Only)

    4-18. Equipment DIP Switch Settings (For Models With Meters Only) Digital Meter DIP Switch Setting Inches/Minute Meters/Minute PC60 Remove wrapper. DIP Switch S2 On Digital Meter Board PC60 Install wrapper when finished. Tools Needed: 1/4 in Ref. 803 154 / 803 188 OM-230 300 Page 21...

  • Page 26: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Power Switch 5-2. Left/Right Select Switch 5-3. Jog/Purge OM-230 300 Page 22 Power Switch Ref. 803 183 Left/Right Select Switch Pressing the Left/Right Select switch allows the operator to choose which side of the unit’s con- trols will operate.

  • Page 27: Trigger Hold Switch

    5-4. Trigger Hold Switch 5-5. Voltage Control And Digital Meters Trigger Hold Switches Trigger hold allows the operator to weld without holding the gun trigger. To use the trigger hold function, place the trigger hold switch in the On position. The operator must hold the trig- ger for a minimum of 2 seconds, but not longer than 6 seconds be-...

  • Page 28: Section 6 − Maintenance

    SECTION 6 − MAINTENANCE 6-1. Routine Maintenance n = Check ~ = Clean Every Months l Unreadable Labels ~ Weld Terminals n 14-Pin Cord n Gas Hose and Fittings Every Months ~ Inside Unit ~ Drive Rolls 6-2. Brush Inspection And Replacement OM-230 300 Page 24 Y Disconnect power before maintaining.

  • Page 29: Diagnostics

    6-3. Diagnostics Left Side Motor Control Left Side Motor Control Board PC101 Right Side Motor Control Right Side Motor Control Board PC1 Dual Board PC70 *Since blink On time and blink Off time are equal in a four-blink cycle, the four−blink sequence appears as constant blinking. Error Indications Error conditions are indicated by LED3 on PC1, PC101 and LED4 on PC70.

  • Page 30: Troubleshooting

    6-4. Troubleshooting Trouble Wire feeds, shielding gas flows, but Check cable connections. Check cables for continuity, and repair or replace cables if necessary electrode wire is not energized. (see Section 4-6). Wire feeder is on, display does not light Check and reset circuit breaker at welding power source. up, motor does not run, gas valve and welding power source contactor do not pull in.
  • Page 31 Notes OM-230 300 Page 27...

  • Page 32: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram OM-230 300 Page 28...
  • Page 33 204 716-B OM-230 300 Page 29...

  • Page 34: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 804 785-A Figure 8-1. Main Assembly OM-230 300 Page 30...
  • Page 35 Item Dia. Part Mkgs....See Note ..... 201 319 .
  • Page 36 Item Dia. Part Mkgs....204 722 ..... 134 464 .
  • Page 37 Item Dia. Part Mkgs..R1,101 ..073 562 . . . 17 R1,101,70,170 224 597 ....204 723 .
  • Page 38 Hardware is common and not available unless listed. 804 786-A Figure 8-3. Boom Assembly OM-230 300 Page 34...
  • Page 39 Item Part Figure 8-3. Boom Assembly (Fig 8-1 Item 13) ... . 010 313 Pin, Cotter Hair .072 X 1.437 ... . 010 910 Washer, Flat Stl Sae .375 .
  • Page 40 Hardware is common and not available unless listed. Item Diagram Part marking ....230 247 ....230 248 .
  • Page 41 Figure 8-5. Drive Assembly With Motor (Left Side Shown) Item Diagram Part marking ....223 252 ....190 742 .
  • Page 42 Item Part Figure 8-6. Support, Hub & Reel (Fig 8-1 Item 10) ..058 427 RING, retaining spool ..136 684 NUT, stl slflkg hex reg .625-11 w/nyl insert .
  • Page 43 OM-230 300 Page 39...
  • Page 44 Notes...
  • 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: Options And Accessories

    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...

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