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Miller Electric S-75D Owner's Manual

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www.MillerWelds.com
S-75S, S-75D
OM-223 605A
May 2005
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder

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Summary of Contents for Miller Electric S-75D

  • Page 1 S-75S, S-75D Visit our website at www.MillerWelds.com OM-223 605A May 2005 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding (Gas- And Self-Shielded) Description Wire Feeder...
  • 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 catalog 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 − 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: Symbols And Definitions

    3-2. Symbols And Definitions Note Some symbols are found only on CE products. Amperes Degree Of Protection Set Up Purge Time Increase Primary Voltage Notes OM-223 605 Page 10 Volts Hertz Output Sequence Press To Set Preflow Time Primary Current Dual Schedule Alternating Current Duty Cycle...

  • 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 Voltage and Current...

  • Page 16: Rear Panel Connections And Rotating Drive Assembly

    5-2. Rear Panel Connections And Rotating Drive Assembly Tools Needed: 9/16 in OM-223 605 Page 12 0 to 350 Amps weld connection 14-Pin Control Cable - 10 ft (3.0 m) Shielding Gas Valve Fitting Connect customer-supplied gas hose with 5/8-18 right-hand threads.

  • Page 17: 14-Pin Plug Plg12 Information

    5-3. 14-Pin Plug PLG12 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 18: Installing Pd Continuous Wire Guides

    5-7. Installing PD Continuous Wire Guides OM-223 605 Page 14 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.

  • Page 19: Installing Non-Pd (Old Style) Wire Guides

    5-8. Installing Non-PD (Old Style) Wire Guides 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 lo- cated between the lower front and rear drive roll carriers).

  • Page 20: Installing Welding Gun

    5-9. Installing Welding Gun Installing gun with Accu-Mate connection. OM-223 605 Page 16 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 21: Installing Welding Wire And Adjusting Pressure Drive Setting

    5-10. 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 9 with...

  • Page 22: Setting Internal Dip Switches

    5-11. Setting Internal DIP Switches Position Settings And Results For DIP Switch S1 On PC1 Run-In Enabled (Factory Default) S1-1 Run-In feature is available. Run-In feature is not avail- X - Means switch may be in either able. X - Means switch may be in either position.

  • Page 23: Equipment Dip Switch Settings (For Models With Meters Only)

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

  • Page 24: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Power Switch 6-2. Jog/Purge And Trigger Hold OM-223 605 Page 20 Power Switch 804 182-A 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.

  • Page 25: Voltage Control And Digital Meters (For Models With Meters Only)

    6-3. Voltage Control And Digital Meters (For Models With Meters Only) SECTION 7 − MAINTENANCE 7-1. Routine Maintenance 3 Months Replace unreadable labels. Replace Check cracked 14-pin cord. parts. 6 Months Blow out or vacuum inside. During heavy service, clean monthly.

  • Page 26: Diagnostics

    7-2. Diagnostics Display On Meter (If Equipped) HELP 11 HELP 12 HELP 13 HELP 14 *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 or on display (on models with meters).

  • Page 27: Troubleshooting

    7-3. 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 5-2). 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 28: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM 202 246-B Figure 8-1. Circuit Diagram OM-223 605 Page 24...
  • Page 29 Notes OM-223 605 Page 25...

  • Page 30: Section 9 − Parts List

    SECTION 9 − PARTS LIST Fig 9-3, 9-4 Fig 9-2 OM-223 605 Page 26 Figure 9-1. Main Assembly Hardware is common and not available unless listed. 804 185-A...
  • Page 31 Item Item Part Part ....159 647 ....159 646 .
  • Page 32 ........Hardware is common and not available unless listed. Quantity Model S-75S S-75D .....
  • Page 33 ........Quantity Model S-75S S-75D ... .
  • Page 34 Hardware is common and not available unless listed. See Table 9-1 For Drive Roll & Wire Guide Kits Item Item Part Part ....224 772 .
  • Page 35 ......804 191-A Quantity Model S-75S S-75D .....
  • Page 36 OM-223 605 Page 32...
  • Page 37 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org...
  • Page 38 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 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)
  • Page 39 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after for your local the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • 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. 2005 Miller Electric Mfg. Co. 1/05 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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