Related Manuals for Miller Electric D-75D
Summary of Contents for Miller Electric D-75D
- Page 1 D-75S, D-75D Visit our website at www.MillerWelds.com OM-228 322A 2006−06 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding (Gas- And Self-Shielded) Description Wire Feeder 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.
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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 4 Declaration of Conformity for European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Manufacturer: Miller Electric Mg. Co. 1635 W. Spencer St. Appleton, WI 54914 USA Phone: (920) 734-9821 European Contact Signature:...
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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 − Definitions
SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions S-178 936 A. Warning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. Welding wire and drive parts are at welding voltage during operation −... -
Page 14: Weee Label
3-2. WEEE Label 3-3. Rating Label For CE Products For label location see Section 5-3. 3-4. Symbols And Definitions Note Some symbols are found only on CE products. Amperes Degree Of Protection Set Up Purge Time Increase Primary Voltage OM-228 322 Page 10 S/N: 50/60 IP 21... -
Page 15: Section 4 − Introduction
SECTION 4 − INTRODUCTION 4-1. Specifications Welding Type of Input Welding Power Circuit Power Source Type Rating 24 Volts ac Constant 100 Volts, Single-Phase Voltage (CV) 750 Amperes, 10 Amperes DC With 14-Pin, 100% Duty 50/60 Hertz that Provides Cycle Voltage and Current Feedback... -
Page 16: Equipment Connection Diagrams
5-2. Equipment Connection Diagrams OM-228 322 Page 12 Welding Power Source Contactor Control/Power Cord Weld Cable Weld Cable Workpiece Welding Gun Wire Feeder Gas Hose Gas Cylinder and Regulator (Customer Supplied) Shielding gas pressure not to exceed 100 PSI (689 kPa). 804 564-B... -
Page 17: Rear Panel Connections And Rotating Drive Assembly
5-3. Rear Panel Connections And Rotating Drive Assembly Tools Needed: 9/16, 5/8 in 14-Pin Control Cable - 10 Ft (3.0 m) Shielding Gas Valve Fittings Requires fitting with 5/8-18 right-hand threads. Connect customer-supplied gas hose. Jumper Weld Cable If welding at 350 amps or less, connect jumper weld cable to connection point B. -
Page 18: 14-Pin Plug Information
5-4. 14-Pin Plug Information Pin* 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. Remote control circuit common. -
Page 19: Installing Pd Continuous Wire Guides
5-8. Installing PD Continuous Wire Guides PD Continuous 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. -
Page 20: Installing Non-Pd (Old Style) Wire Guides
5-9. Installing Non-PD (Old Style) Wire Guides OM-228 322 Page 16 Installing wire guides with non- PD (old-style) drive rolls Open pressure door assembly. 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 21: Installing Welding Gun
5-10. 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 22: Installing Welding Wire And Adjusting Pressure Drive Setting
5-11. 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 door as- sembly not shown. No Wire Slip Wire Slips NONCONDUCTIVE NONCONDUCTIVE SURFACE SURFACE Drive Roll Pressure Adjustment Lever Notch In Lever (Indicates Pressure Settings) -
Page 23: Motor Board Dip Switch Settings
5-12. Motor Board DIP Switch Settings Right Side Motor Control Board PC1 Position Settings And Results For DIP Switch S1 On PC1 And PC101 Run-In Enabled (Factory Default) S1-1 Run-In feature is not avail- Run-In feature is available. able. X - Means switch may X - Means switch may be in either be in either position. -
Page 24: Display Board Dip Switch Settings
5-13. Display Board DIP Switch Settings OM-228 322 Page 20 Digital Meter Functions Inches/Minute Meters/Minute PC60 Remove wrapper. DIP Switch S2 On Digital Meter Board PC60 Install wrapper when finished. Tools Needed: 1/4 in 803 069... -
Page 25: Section 6 − Operation
SECTION 6 − OPERATION 6-1. Power Switch 6-2. Left/Right Select Switch 6-3. Jog/Purge Pressing the Jog/Purge switch allows the op- erator to jog wire without energizing the weld power or gas valve circuit. Jog speed can be adjusted with the Wire Speed control when the unit is jogging wire. -
Page 26: Trigger Hold Switch
6-4. Trigger Hold Switch 6-5. Voltage Control And Digital Meters OM-228 322 Page 22 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. -
Page 27: Section 7 − Maintenance
SECTION 7 − MAINTENANCE 7-1. 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 7-2. Brush Inspection And Replacement Y Disconnect power before maintaining. -
Page 28: Diagnostics
7-3. Diagnostics Left Side Motor Control Board PC101 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, PC70 or on display if meter op- tion is present. -
Page 29: Troubleshooting
7-4. 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 5-3). 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 30: Section 8 − Electrical Diagram
SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram OM-228 322 Page 26... - Page 31 204 716-B OM-228 322 Page 27...
- Page 32 SECTION 9 − PARTS LIST Fig. 9-3 Fig.9-2 OM-228 322 Page 28 Figure 9-1. Main Assembly Hardware is common and not available unless listed. 804 569-B...
- Page 33 Item Part ....159 647 ....159 646 .
- Page 34 Circuit Card Assy, Master W/Program Hardware is common and not available unless listed. 803 049-C Quantity Model D-75S D-75D ..... .
- Page 35 . . . Housing Rcpt+Skts, (Service Kit) . . . Housing Plug+Skts, (Service Kit) Quantity Model D-75S D-75D ..... . .
- Page 36 See Table 9-1 For Drive Roll & Wire Guide Kits Figure 9-3. Drive Assembly, Wire (Left Side Drive Assembly Shown) Item Diagram Part marking ....230 247 .
- Page 37 ......Adapter, Optical Encoder (Standard Speed Motor) 804 191-B Quantity Model D-75S D-75D .....
- Page 38 OM-228 322 Page 34...
- Page 39 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.
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Page 40: 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...