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Miller Electric S-62 Owner's Manual

Miller mig (gmaw) welding flux cored (fcaw) welding (gas- and self-shielding) submerged (saw) welding owner's manual s-62 & s-64
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Visit our website at
www.MillerWelds.com
S-62 & S-64
OM-1579
133 566V
September 2001
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- and Self-Shielding)
Submerged (SAW) Welding
Description
Wire Feeder
(Use with CV Power Sources)

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Summary of Contents for Miller Electric S-62

  • Page 1 Visit our website at www.MillerWelds.com S-62 & S-64 OM-1579 133 566V September 2001 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding (Gas- and Self-Shielding) Submerged (SAW) Welding Description Wire Feeder (Use with CV Power Sources)
  • Page 2 ISO 9001 Quality System Standard. service information for your 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

    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 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION for welding or cutting, 1-1.
  • 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). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA S-62 & S-64...

  • 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. Y Marks 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.

  • 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’...

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. Signifie NOTA ;...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer 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

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. D Ne pas placer l’appareil sur, au-dessus ou à proxi- mité de surfaces infllammables. D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique –...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. 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: Rating Label For Ce Products

    2-2. Rating Label For CE Products For label location see Section 4-4. 2-3. Symbols And Definitions Note Some symbols are found only on CE products. Amperes Degree Of Protection Press To Set Purge Burnback Time Increase Primary Voltage OM-1579 Page 10 S/N: 50/60 50/60...

  • Page 15: 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 And 10 Amperes Contactor Control 50/60 Hertz SECTION 4 – INSTALLATION 4-1. Site Selection Welding Wire Feed Wire Diameter Circuit Speed Range...

  • Page 16: Gun Recommendation Table

    4-2. Gun Recommendation Table Process GMAW – Hard or Cored Wires Roughneck C-Series Guns: 300, 400, 500, FCAW – Self-Shielding Wires 4-3. Equipment Connection Diagrams OM-1579 Page 12 And 600 Amp. FC-1260 Or FC-1150 Welding Power Source Contactor Control/Power Cord Positive (+) Weld Cable Negative (–) Weld Cable Workpiece...

  • Page 17: Rear Panel Connections And Rotating Drive Assembly

    4-4. Rear Panel Connections And Rotating Drive Assembly Tools Needed: 9/16, 5/8 in 3/16 in Customer Supplied Gas Hose Shielding Gas Valve Fitting Requires fitting with 5/8-18 right- hand threads. Optional Current Sensor Connection Power Switch 14-Pin Cord Weld Cable Weld Cable Terminal Drive Assembly To rotate the drive assembly, loos-...

  • Page 18: 14-Pin Plug Information

    4-5. 14-Pin Plug Information Pin* *The remaining pins are not used. 4-6. Wire Type, Size, And Feed Speed Capability Table Motor Speed Wire Type Standard Standard Standard Optional High Speed 4-7. Motor Start Control Tools Needed: Non-Conductive 1/4 in OM-1579 Page 14 Pin Information 24 volts ac with respect to socket G.

  • Page 19: Installing And Threading Welding Wire

    4-8. Installing And Threading Welding Wire 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. Install gun.

  • Page 20: Optional Equipment Dip Switch Settings

    4-9. Optional Equipment DIP Switch Settings Spot Time Range Selection X Means switch can be in either position. . Means switch must be in this position. Tools Needed: 1/4 in OM-1579 Page 16 If wire feeder is equipped with a voltage sensing lead, set DIP switch S3 to the OFF position (up).

  • Page 21: Section 5 - Operation

    SECTION 5 – OPERATION 5-1. Front Panel Controls Voltmeter (Optional) (See Section NO TAG) Wire Speed Meter (Optional) Factory set to display inches per minute. If display of meters per minute is desired, see Section 4-9. Schedule A Wire Speed Control The scale is calibrated in inches per minute x 100 and meter per minute.

  • Page 22: Overload Protection And Optional Side Panel Controls

    5-2. Overload Protection And Optional Side Panel Controls SECTION 6 – MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance 3 Months Replace unreadable labels. Replace Check cracked 14-pin parts. cord. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. OM-1579 Page 18 Y Disconnect power before maintaining.

  • Page 23: Troubleshooting

    6-2. Troubleshooting Trouble Wire feeds, shielding gas flows, but Check interconnecting cord connections. If secure, check cord for continuity and repair or replace electrode wire is not energized. (see Sections 4-3 and 4-4). Wire feeder is on, meter(s) do not light Check and reset CB1 (see Section 5-2).

  • Page 24: Section 7 - Electrical Diagram

    SECTION 7 – ELECTRICAL DIAGRAM Figure 7-1.Circuit Diagram OM-1579 Page 20...
  • Page 25 196 503–A OM-1579 Page 21...

  • Page 26: Section 8 - Parts List

    SECTION 8 – PARTS LIST Fig 8-4 OM-1579 Page 22 Fig 8-2 Figure 8-1. Main Assembly Hardware is common and not available unless listed. ST-136 987-K...
  • Page 27 Item Part ....141 753 ....058 427 .
  • Page 28 Hardware is common and not available unless listed. *See option that is applicable OM-1579 Page 24 Fig 8-3 Figure 8-2. Control Box Ref. ST-142 438-G...
  • Page 29 Item Dia. Part Mkgs....048 282 ... . . 134 847 ..
  • Page 30 Item Dia. Part Mkgs....173 750 ....134 209 .
  • Page 31 Item Dia. Part Mkgs... 011 770 . . . PC70 . . . +150 591 ..PLG54,76 +115 093 ..
  • Page 32 Hardware is common and not available unless listed. See Table 8-1 For Drive Roll & Wire Guide Kits 802 458 Figure 8-4. Drive Assembly, Wire OM-1579 Page 28...
  • Page 33 Item Dia. Part Mkgs....010 668 ....172 075 .
  • Page 34 Wire Size 2 Roll Fraction Metric .023-.025 in. 0.6 mm 150 993 149 518 151 030 .030 in. 0.8 mm 150 993 149 518 151 031 .035 in. 0.9 mm 150 993 149 518 151 032 .040 in. 1.0 mm 150 993 149 518 161 189...
  • Page 35 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.
  • Page 36 Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2000 Miller Electric Mfg. Co. 6/00 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 &...

This manual is also suitable for:

S-64

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