1. Manuals
  2. Brands
  3. Miller Electric Manuals
  4. Welding Accessories
  5. DS-64M Swingarc
  6. Owner's manual

Miller Electric DS-64M Swingarc Owner's Manual

Wire feeder
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Visit our website at
www.MillerWelds.com
DS-64M Swingarc
OM-1588
161 875S
2006−05
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Description
Wire Feeder
(Use with CC/CV Power Sources)
12 and 16 Foot
File: MIG (GMAW)

Advertisement

Table of Contents
loading

Related Manuals for Miller Electric DS-64M Swingarc

Summary of Contents for Miller Electric DS-64M Swingarc

  • Page 1 DS-64M Swingarc Visit our website at www.MillerWelds.com OM-1588 161 875S 2006−05 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding Description Wire Feeder (Use with CC/CV Power Sources) 12 and 16 Foot 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 4 TABLE OF CONTENTS SECTION 10 − STANDARD PULSE WELDING PROGRAMS FOR PHOENIX/INVISION 456 INVERTER WELDING POWER SOURCES ..............10-1.

  • 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 − À 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: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil

    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 For GMAW Or 10 Amperes Constant Voltage (CV) / 50/60 Hertz Constant Current (CC) DC For GMAW-P All Need 14-Pin And Contactor Control Maximum Height With 4 ft (1.2 m) Post Vertical Lift Of Boom...

  • Page 14: Installing Control Box And Adjusting Tilt

    4-2. Installing Control Box And Adjusting Tilt Tools Needed: 4-3. Installing Boom And Reel Support Tools Needed: 3/8, 3/4 in OM-1588 Page 10 Weld Control Bracket Screw Bracket and screws are installed onto bottom of control at factory. Swivel Loosen screws. Place control on swivel and slide forward.

  • Page 15: Installing Wire Guide Extension

    4-4. Installing Wire Guide Extension Tools Needed: 3/8 in Wire Guide Fitting Bolt Monocoil Liner Wire Guide Extension Tighten bolt to secure liner in wire guide fitting. Do not overtighten bolt and crush liner. Repeat procedure for opposite side. ST-152 383 OM-1588 Page 11...

  • Page 16: Equipment Connection Diagram

    4-5. Equipment Connection Diagram OM-1588 Page 12 300/400 Ampere Model CC/CV Inverter Welding Power Source Use settings shown for both pulse MIG welding and MIG welding. 450 Ampere Model CV Inverter Welding Power Source 14-Pin Cord Positive (+) Weld Cable Negative (−) Weld Cable Be sure weld cables are sized prop- erly for peak amperage if pulse...

  • Page 17: Connecting Weld Cables And Gas Hoses

    4-6. Connecting Weld Cables And Gas Hoses Tools Needed: 5/8 in Gas Supply Boom The weld cables and shielding gas hoses extend 10 ft (3 m) from the boom. Route weld cables from boom through reed relays, if applicable. If the welding power source or gas supply are further from the boom, extend cables or hoses as follows: Weld Cable...

  • Page 18: Control Box Connections

    4-7. Control Box Connections 4-8. 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 output to remote control with respect to socket D. Remote control circuit common.

  • Page 19: 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 Standard Standard Optional High...

  • Page 20: Installing And Threading Welding Wire

    4-12. Installing And Threading Welding Wire Install wire spool. Ad- just tension nut so wire is taut when wire feed stops. Install drive rolls. NONCONDUCTIVE SURFACE No Wire Slip Be sure that outlet cable has proper size liner for the welding wire size. When installing gun, position liner extending from outlet wire guide as close as pos- sible to drive rolls without touching.

  • Page 21: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Operational Terms Note See Menu Guide for detailed programming steps. The following is a list of terms and their definitions as they apply to this wire feeder: General Terms: Adaptive Pulse Welding The wire feeder automatically regulates pulse frequency to maintain a constant arc length, regardless of change in welding wire stickout.

  • Page 22: Front Panel Controls

    5-3. Front Panel Controls Display Parameter Select Button > Press button to move (the cursor) on the display. Display Control Turn control to change value pointed to by Turning control one click causes Trim (arc length) to increase/decrease by one or Volts to increase/decrease by 0.1.

  • Page 23: Section 6 − Setting Sequence Parameters

    SECTION 6 − SETTING SEQUENCE PARAMETERS 6-1. Sequence Parameters In A Program Pulse 1. Weld Pulse 2. Crater 3. Burnback Pulse 4. & 5. Postflow/ Preflow 6. Run-In Pulse 6. Start X = Setting available. Start Time Preflow Time Run-In Preflow Strike Trigger...

  • Page 24: Section 7 − Setting Dual Schedule Parameters

    SECTION 7 − SETTING DUAL SCHEDULE PARAMETERS 7-1. Selecting Dual Schedule Pair > P r g P r o c e s s S e q u e n c e > D u a l S chd C a r d 1 8 .

  • Page 25: Optional Dual Schedule Switch Diagrams

    7-2. Optional Dual Schedule Switch Diagrams DSS-10 DSS-8 Adapter DSS-9M Trigger Momen 2P (Momentary-Contact 2-Pole Switch) Maint 2P (Maintained-Contact 2-Pole Switch) Maint 1P (Maintained-Contact 1-Pole Switch) Trigger Allows dual scheduling establishing a welding arc. Momen 1P (Momentary-Contact 1-Pole Switch) If trigger is used for dual sched- ule switch, Trigger Hold is dis- abled.

  • Page 26: Section 8 − Using The Optional Data Card

    SECTION 8 − USING THE OPTIONAL DATA CARD 8-1. Data Card Terms WRITE Programs To Card READ Programs From Card Amperage Apk (Peak Amperage) (Background Amperage) 8-2. Installing Data Card OM-1588 Page 22 CARD SCREEN TERMS >W r i t e R e a d D e l e t e D o n e...

  • Page 27: Card Displays

    8-3. Card Displays S e q u e n c e D u a l S c h d >C a r d S e c u r i t y >W r i t e R e a d D e l e t e D o n e P r e s s...

  • Page 28: Entering Access Code

    8-4. Entering Access Code Access code works only when a data card is inserted and access mode in Setup screen is turned On. Press Mode Select 5 Times Turn Unit E n t e r > C od e A c c e s s C od e N e x t C h a r .

  • Page 29: Security

    8-5. Security The security feature works only when a data card is inserted. Press Mode Select 5 Times Turn Unit P r o g P r o g L o c k >L o c k >T r i m T r i m R a n g e R a n g e...

  • Page 30: Section 9 − System Setup

    SECTION 9 − SYSTEM SETUP 9-1. Accessing The Setup Menu S e t u p Main Display System > Invisn 456 > Model Access System Mig Type Reset Now See Section 9-2 System Setup Display Parameters OM-1588 Page 26 Mode Parameter Select Select...

  • Page 31: System Setup Display Parameters

    9-2. System Setup Display Parameters Note See Menu Guide for detailed programming steps. DISPLAY SETTING NOTES >System Select the process the welding power source is able to do. >Model For the Invision 456 and XMT 304 selections, pulse data and welding power source minimum and maximum voltage values are automatically loaded in.

  • Page 32: Section 10 − Standard Pulse Welding Programs

    SECTION 10 − STANDARD PULSE WELDING PROGRAMS FOR PHOENIX/INVISION 456 INVERTER WELDING POWER SOURCES Note Apk = Peak Amperage, Vpk = Peak Voltage, Abk = Background Amperage, PPS = Pulses Per Second, PWms = Pulse Width (milliseconds). The following eight pulse welding programs are in the memory of the wire feeder.

  • Page 33: Program 4 − Steel

    10-4. Program 4 − Steel Wire Size/Type: .062” IPM / MPM 400 / 10.2 36.8 300 / 7.6 36.3 200 / 5.1 31.6 100 / 2.5 28.7 10-5. Program 5 − Stainless Steel Wire Size/Type: .035” IPM / MPM 700 / 17.8 33.9 400 / 10.2 31.6...

  • Page 34: Section 11 − Standard Pulse Welding Programs

    SECTION 11 − STANDARD PULSE WELDING PROGRAMS FOR XMT 304 INVERTER WELDING POWER SOURCES Note Apk = Peak Amperage, Vpk = Peak Voltage, Abk = Background Amperage, PPS = Pulses Per Second, PWms = Pulse Width (milliseconds). The following eight pulse welding programs are in the memory of the wire feeder.

  • Page 35: Program 4 − Stainless Steel

    11-4. Program 4 − Stainless Steel Wire Size/Type: .030” IPM / MPM 700 / 17.8 34.1 400 / 10.2 31.7 200 / 5.1 30.1 100 / 2.5 29.9 11-5. Program 5 − Stainless Steel Wire Size/Type: .035” IPM / MPM 700 / 17.8 35.8 400 / 10.2...

  • Page 36: Section 12 − Setting Sharparce Control

    SECTION 12 − SETTING SharpArcE CONTROL 12-1. Selecting And Adjusting SharpArcE Control T r i m 2 0 0 Parameter Select T r i m 2 0 0 T r i m 2 0 0 OM-1588 Page 32 > P r g I P M 0 3 5 “...

  • Page 37: Section 13 − Teach Points

    SECTION 13 − TEACH POINTS 13-1. Teach Using 15 Points IPM / MPM 780 / 19.8 750 / 19.1 700 / 17.8 650 / 16.5 600 / 15.2 550 / 14.0 500 / 12.7 450 / 11.4 400 / 10.2 350 / 8.9 300 / 7.6 250 / 6.4...

  • Page 38: Redefining Teach Points

    13-2. Redefining Teach Points Redefining IPM Teach Point > 4 5 0 Purge > 4 6 0 Redefining Pulse Parameters T e a c h P r o c e s s 4 0 0 >3 2 . 4 3 8 5 4 0 0 I P M 3 2 .
  • Page 39 Date Program Number Wire Manufacturer Equipment Used − Power Source Wire Feeder Gun Model IPM / MPM Preflow Seconds: Run In IPM: Start Trim/Volts: IPM / MPM: Crater Trim/Volts: IPM / MPM: Burnback Volts/Seconds: SharpArc: Arc Start: Wire Size/Type Flowrate Weld Cable −...

  • Page 40: Section 14 − Maintenance And Troubleshooting

    SECTION 14 − MAINTENANCE AND TROUBLESHOOTING 14-1. 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. 14-2. Motor Start Control Right Side Tools Needed: Non-Conductive 1/4 in OM-1588 Page 36...

  • Page 41: Error Displays

    14-3. Error Displays R e l e a s e T r i g g e r V o l t S e n s e d E r r o r M e m o r y P r g C R C E r r o r M e m o r y...

  • Page 42: Troubleshooting

    14-4. Troubleshooting Trouble Wire feeds, shielding gas flows, but elec- Check interconnecting cord connections. If secure, check cord for continuity and repair or replace (see trode wire is not energized. Sections 4-5 and 4-7). Wire feeder is on, meter(s) do not light Check and reset CB1 (see Section 5-4).
  • Page 43 Notes OM-1588 Page 39...

  • Page 44: Section 15 − Electrical Diagram

    SECTION 15 − ELECTRICAL DIAGRAM Figure 15-1. Circuit Diagram OM-1588 Page 40...
  • Page 45 SD-184 792-B OM-1588 Page 41...

  • Page 46: Section 16 − Parts List

    SECTION 16 − PARTS LIST Hardware is common and not available unless listed. 800 272-D Figure 16-1. Main Assembly OM-1588 Page 42...
  • Page 47 Item Dia. Part Mkgs....149 251 ....149 252 .
  • Page 48 Item Part Figure 16-2. Support, Hub & Reel (Fig 16-1 Item 12) ..058 427 RING, retaining spool ..136 684 NUT, stl slflkg hex reg .625-11 w/nyl insert .
  • Page 49 Item Dia. Part Mkgs........... . 167 697 .
  • Page 50 Hardware is common and not available unless listed. ST-800 273-B Figure 16-4. Control Box OM-1588 Page 46...
  • Page 51 Item Dia. Part Mkgs..... 162 253 ..RC30,40 ..047 637 .
  • Page 52 Hardware is common and not available unless listed. See Table 16-1 For Drive Roll & Wire Guide Kits OM-1588 Page 48 Figure 16-5. Drive Assembly, Wire ST-801 456−A...
  • Page 53 Item Dia. Part Mkgs....010 668 ....172 075 .
  • Page 54 Wire Size Metric Fraction .023-.025 in. 0.6 mm 150 993 149 518 .030 in. 0.8 mm 150 993 149 518 .035 in. 0.9 mm 150 993 149 518 .040 in. 1.0 mm 150 993 149 518 .045 in. 1.1/1.2 mm 150 994 149 519 .052 in.
  • Page 55 Item Dia. Part Mkgs..... 147 139 ....155 024 .
  • Page 56 Hardware is common and not available unless listed. ST-142 306-G Figure 16-7. Boom Assembly OM-1588 Page 52...
  • Page 57 Item Part Figure 16-7. Boom Assembly (Fig 16-1 Item 15) ... . 010 313 PIN, cotter hair .072 x 1.437 ... . 010 910 WASHER, flat stl SAE .375 .
  • Page 58 Notes OM-1588 Page 54...
  • Page 59 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 60: 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...

Table of Contents