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Summary of Contents for Miller Electric DS-2
- Page 1 Visit our website at www.MillerWelds.com OM-197 509B July 2002 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder DS-2...
- Page 2 ISO 9001 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 orindividual catalog sheets.
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Page 3: Table Of Contents
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage 1-2. Arc Welding Hazards 1-3. Additional Symbols For Installation, Operation, And Maintenance WARNING 1-4. Principal Safety Standards 1-5. EMF Information This product, when used SECTION 2 – DEFINITIONS for welding or cutting, 2-1. -
Page 5: Section 1 - Safety Precautions - Read Before Using
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. YMarks a special safety message. Means “Note”; not safety related. 1-2. - 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: Emf Information
1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power-... -
Page 9: Section 2 - Definitions
SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions 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 – keep hands and metal objects clear. -
Page 10: Section 3 - Installation
SECTION 3 – INSTALLATION 3-1. Specifications Welding Power Type of Input Source Type Power 24 Volts DC (5 Deltaship Amp) For Wire Constant Voltage Feed Motor (CV) DC With 24 Volts AC (0.5 10-Pin Receptacle Amp) For Gas Valve 3-2. Site Selection OM-197 509 Page 6 Wire Wire Feed... -
Page 11: Equipment Connection Diagrams
3-3. Equipment Connection Diagrams 3-4. Installing Wire Guides And Drive Rolls Tools Needed: Corresponding 1.2 mm Wire Groove 1.2 mm 1.2 mm Wire Size Stamp Deltaship 502 Welding Power Source With 24 VAC Power 10-Pin Control Cord Positive Weld Cable (Customer Supplied) Work Cable (Customer Supplied) -
Page 12: 10-Pin Plug Plg8 Information
3-5. 10-Pin Plug PLG8 Information 3-6. 7-Pin Plug PLG1 Information 197 504 3-7. 10-Pin Plug And Shielding Gas Connections Tools Needed: 11/16 in OM-197 509 Page 8 Pin Information 24 volts ac for gas valve control when triggered or purging gas. +15 volts dc with gun trigger open;... -
Page 13: Connecting Weld Cable
3-8. Connecting Weld Cable Setscrew Sleeve Connector Body (Male Or Female) A. Push weld cable through insulator as shown. B. Remove 1 in. (25 mm) of insulation from end of cable. C. Install supplied sleeve on stripped end of cable. D. -
Page 14: Connecting Welding Gun
3-9. Connecting Welding Gun 3-10. Changing Nameplates Tools Needed: 5/16 in OM-197 509 Page 10 Loosen knob. Slide gun end as far as possible into gun block and tighten gun se- curing knob. Connect gun trigger plug to match- ing receptacle on wire feeder. Pendant has three nameplates stacked one on top of the other. -
Page 15: 3-11.Installing Wire Spool And Adjusting Hub Tension
3-11. Installing Wire Spool And Adjusting Hub Tension Tools Needed: 15/16 in Hub Support Arm Spool Hub Retaining Ring Hub Pin Remove retaining ring. Slide wire spool onto spool hub so wire feeds off bottom of spool . Install spool so hub pin fits spool hole. -
Page 16: 3-12.Threading Welding Wire
3-12. Threading Welding Wire Tighten WOOD OM-197 509 Page 12 Pressure Assembly Pressure Assembly Adjustment Knob Lay gun cable out straight. Open pressure assembly, hold wire tightly, and cut off end. Push wire through guides into gun. Close and tighten pressure assembly, and let go of wire. -
Page 17: Section 4 - Operation
SECTION 4 – OPERATION 4-1. Pendant Controls Controls are pendant mounted. An optional remote pendant extension cord is available. Nameplate Pendant has three nameplates stacked one on top of the other. Each nameplate contains the voltage and amperage range for a differ- ent size flux cored welding wire (for reference only). -
Page 18: Section 5 - Maintenance & Troubleshooting
SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Replace Unreadable Labels 10-Pin Cord 5-2. Troubleshooting Trouble No weld output; unit completely Place line disconnect switch in On position (see welding power source owner’s manual). inoperative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see welding power source owner’s manual). - Page 19 Trouble Fan in welding power source not oper- Check for and remove anything blocking fan movement. ating. Note: fan runs only when cool- ing is necessary. Have Factory Authorized Service Agent check fan motor. Wire does not feed, unit completely Check 10–pin plug PLG8 connections (see Section 3-7).
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Page 20: Section 6 - Electrical Diagram
SECTION 6 – ELECTRICAL DIAGRAM 203 365 Figure 6-1. Circuit Diagram For Wire Feeder OM-197 509 Page 16... - Page 21 Notes OM-197 509 Page 17...
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Page 22: Section 7 - Parts List
SECTION 7 – PARTS LIST OM-197 509 Page 18 Figure 7-1. Main Assembly Hardware is common and not available unless listed. Fig 7-2 Ref. 802 586... - Page 23 Item Part ....072 094 Hub+Spindle Assy, ... . . +196 937 Assembly, Frame ....196 954 Grip, Handle .
- Page 24 Hardware is common and not available unless listed. Item Dia. Part Mkgs..196949 ... Box, Pendant ..035897 ... Pot, Cp Std Slot 1t 2.
- Page 27 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
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Page 28: Owner's Record
Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2002 Miller Electric Mfg. Co. 5/02 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...
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