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We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.
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Via Privata Iseo 6/E 20098 San Giuliano Milanese, Italy Phone: 39(02)98290-1 Fax: 39(02)98290203 European Contact Signature: S-75S, S-75SA, S-75SC, S-75D, Declares that the product: S-75DA, S-75DC conforms to the following Directives and Standards: Directives Low Voltage Directive: 73/23/EEC Electromagnetic Compatibility (EMC) Directive: 89/336/EEC...
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.
D Read Owner’s Manual before using or servic- support unit. ing unit. D If using lift forks to move unit, be sure forks are D Use only genuine Miller/Hobart replacement long enough to extend beyond opposite side of parts. unit.
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11 ting of Containers and Piping, American Welding Society Standard...
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 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.
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LES RAYONS D’ARC peuvent entraî- ACCUMULATIONS ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures ou même la mort. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation.
D Utiliser un équipement de levage de capacité D Utiliser uniquement des pièces de rechange suffisante pour lever l’appareil. Miller/Hobart. D En utilisant des fourches de levage pour déplacer l’unité, s’assu- rer que les fourches sont suffisamment longues pour dépasser du côté...
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet ternet : www.global.ihs.com). www.csa-international.org).
SECTION 3 − DEFINITIONS 3-1. 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.
3-2. WEEE Label Do not discard this product with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collec- tion facility. Contact your local recycling office or your local distributor for further information. 3-3.
SECTION 4 − INTRODUCTION 4-1. Specifications Welding Wire Type of Input Welding Power Overall Maximum Wire Feed Circuit Diameter Weight Power Source Type Rating Dimensions Spool Weight Speed Range Rating Range 24 Volts ac Constant 100 Volts, IP 21 Length: 27 in 60 lb Standard .023 to 5/64 in...
5-3. Rear Panel Connections And Rotating Drive Assembly 350 Amps and above weld connection point A Up to 350 Amps weld connection point B Connection Connection Point A Point B Tools Needed: 9/16 in Ref. 804 183-B / 804 184-B 14-Pin Control Cable - 10 ft (3.0 m) from connection point A and use it at con- Note two weld cable connections: Up...
5-4. 14-Pin Plug PLG12 Information Pin* Pin Information 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.
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.
5-9. Installing Non-PD (Old Style) Wire Guides Installing wire guides with non- PD (old-style) drive rolls Non-PD (old-style) wire guides and drive rolls should be used with 5/64 in (2.0 mm) and larger diameter wire. Pressure Door Assembly PD Inlet Guide Intermediate Guide Set Screw Guide Holder...
5-10. Installing Welding Gun 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. When installing gun, the liner should extend into the PD continu- ous guide (or exit guide if used) as far as possible without interfering...
5-11. Installing Welding Wire And Adjusting Pressure Drive Setting Install wire spool. Adjust tension nut so wire is taut when wire feed stops. Thread wire. Adjust tension. Drive Rolls Pressure door as- sembly not shown. Back Of Gun End Of Liner Ref.
5-12. Setting Internal DIP Switches Remove wrapper. DIP Switch S1 On Motor Board PC1 S1-1 Run-In enable or disable. S1-2 Automatic Run-In versus Manual Adjustment Run-in Install wrapper when finished. Factory Set Default Set- tings For DIP Switch S1 In the DIP switch S1 illustrations, the elevated slider on each switch is shown in white.
SECTION 6 − OPERATION 6-1. Power Switch Power Switch 804 182-B 6-2. Jog/Purge And Trigger Hold 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. • Jog speed can be adjusted with the Wire Speed control when the unit is jogging wire.
6-3. Voltage Control And Digital Meters (For Models With Meters Only) Voltmeter The voltmeter displays actual or preset voltage from the welding power source through the 14−pin control cable. Voltmeter will not display actu- al or preset voltage if voltage feedback is not provided through the 14-pin control cable.
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power before maintaining. n = Check ~ = Clean l = Replace Reference Every Section 5-2, Months l Unreadable Labels ~ Weld Terminals nl Weld Cable nl Motor Brush Section 5-2, n 14-Pin Cord n Gas Hose and Fittings...
7-3. Diagnostics Wrapper Motor Control Board PC1 LED3 Front panel is shown removed for purpose of illustration only. In actual use, front panel would be in place. Display On LED3 Sequence On Meter Motor Control Board PC1 Indicated Error (If Equipped) HELP 11 1 Blink Communication Error...
7-4. Troubleshooting Y Disconnect power before troubleshooting Trouble Remedy 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.
SECTION 9 − PARTS LIST Hardware is common and not available unless listed. Fig 9-3, 9-4 Fig 9-2 804 185-C Figure 9-1. Main Assembly OM-223 605 Page 28...
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Item Item Part Part Description Description Quantity Quantity Figure 9-1. Main Assembly ....159 647 Insulator, Motor Clamp ......... . .
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Item Diagram Part Model marking Description S-75S S-75D Figure 9-2. Control Box (Figure 9-1 Item 21) ....200 555 Wrapper, Feeder .........
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Diagram Part Model marking Description S-75S S-75D Figure 9-2. Control Box (Figure 9-1 Item 21) ....213 134 Knob, Encoder 1.670 Dia X .250 Id Push On W/Spring .
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Hardware is common and not available unless listed. See Table 9-1 For Drive Roll & Wire Guide Kits 804 186-B Figure 9-3. Drive Assembly, Wire Item Diagram Part marking Description Quantity Figure 9-3. Drive Assembly, Wire (Figure 9-1 Item 4) .
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Diagram Part Model marking Description S-75S S-75D Figure 9-4. Drive Assembly With Motor (Figure 9-1 Item 4) ....219 103 Screw, 010−32x .75 Flathd−Soc Stl Pln (Low Speed) .
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Effective January 1, 2006 (Equipment with a serial number preface of “LG” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions...
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