Miller S-64M Owner's Manual
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Miller S-64M Owner's Manual

Miller S-64M Owner's Manual

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S-64M
OM-1585
155 317P
September 1998
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
(Use With CC/CV Power Sources)

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  • Page 1 OM-1585 155 317P September 1998 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding (Gas- And Self-Shielded) Description Wire Feeder (Use With CC/CV Power Sources) S-64M Visit our website at www.Miller- Welds.com...
  • Page 2 This Owner’s Manual is designed to help you get the most out of your do − every power source from Miller is backed by Miller products. Please take time to read the Safety precautions. They will the most hassle-free war- help you protect yourself against potential hazards on the worksite. We’ve ranty in the business.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ......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-64M...

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 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 D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols for Installation, Operation, and Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

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

    SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT UTILISATION som _nd_fre 5/97 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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • 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 DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • 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- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: 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 14: Manufacturer's Rating Label For Ce Products

    2-2. Manufacturer’s Rating Label For CE Products For label location S/N: see Section 4-3. 50/60 IP 23 10.0 ST-178 794-A 2-3. Symbols And Definitions Note Some symbols are found only on CE products. Output Alternating Current Amperes Volts Duty Cycle Degree Of Hertz Protection...

  • Page 15: Section 3 − Introduction

    SECTION 3 − INTRODUCTION 3-1. Specifications Wire Welding Type of Input Welding Power Wire Feed Overall Diameter Circuit Weight Power Source Type Speed Range Rating Dimensions Range Rating 24 Volts AC Constant Voltage (CV) Standard: 50 To .023 To 1/8 in 100 Volts, IP 23 Length: 26-1/2 in...

  • Page 16: Equipment Connection Diagram

    4-2. Equipment Connection Diagram 300/400 Ampere Model CC/CV Inverter Welding Power Source Use settings shown for both pulse MIG welding and MIG welding. 450 Ampere Model DC 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 welding (see welding power source...

  • Page 17: Rear Panel Connections And Rotating Drive Assembly

    4-3. Rear Panel Connections And Rotating Drive Assembly Customer Supplied Gas Hose Shielding Gas Valve Fitting Requires fitting with 5/8-18 right- hand threads. Voltage Sensing Lead 14-Pin Cord Weld Cable Weld Cable Terminal Drive Assembly To rotate the drive assembly, loosen socket head cap screw, rotate drive assembly, and tighten screw.

  • Page 18: 14-Pin Plug Information

    4-4. 14-Pin Plug 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 output to remote control with respect to socket D. Remote control circuit common.

  • Page 19: Gun Recommendation Table

    4-6. Gun Recommendation Table Process GMAW-P − Hard or Cored Wires GW-500 Or GW-600 GMAW − Hard or Cored Wires M25, M40, Or GA-50C FCAW − Self-Shielding Wires GA-40GL Or GA-50GL 4-7. Wire Type, Size, And Feed Speed Capability Table Motor Speed Wire Type Wire Size...

  • Page 20: Installing And Threading Welding Wire

    4-8. Installing And Threading Welding Wire Install wire guides and If necessary, move hub and spool support anti-wear guide. so wire runs straight from the spool through the drive rolls. Install wire spool. Adjust tension nut so wire is taut when wire feed stops.

  • 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 When IPM is selected, turning control one Trigger Hold can be set on a per program click causes wire feed speed (IPM) to basis. Indicator light comes on for programs Parameter Select Button increase/decrease by one. where this feature is active.

  • Page 23: Side And Rear Panel Controls

    5-4. Side And Rear Panel Controls Mode Display Mode Select Button > Press button to move in display. Parameter Display Parameter Select Button > Press button to move in display. Parameter Increase Button Parameter Decrease Button Power Switch Circuit Breaker CB1 CB1 protects the wire feeder from overload.

  • Page 24: Section 6 − Setting Sequence Parameters

    SECTION 6 − SETTING SEQUENCE PARAMETERS 6-1. Sequence Parameters In A Program See Menu Guide for detailed programming steps. Trim is arc length. If set to zero, arc length is short. If set to 99, arc length is long. If time is set to zero in Weld sequence, welding continues until gun trigger is released.

  • Page 25: Section 7 − Setting Dual Schedule Parameters

    SECTION 7 − SETTING DUAL SCHEDULE PARAMETERS 7-1. Selecting Dual Schedule Pair Dual Schedule is used with two consecutive weld programs 1 & 2, 3 & 4, 5 & 6, or 7 & 8. Any program type (MIG, Adaptive Pulse, or Pulse) can be combined in dual schedule.

  • Page 26: Dual Schedule Switch Diagrams

    7-2. Dual Schedule Switch Diagrams 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 after establishing a welding arc. If trigger is used for dual sched- ule switch, Trigger Hold is dis- abled.

  • Page 27: Installing Data Card

    8-2. Installing Data Card Label Apply label to data card. Write program information on label. Data Card Card Slot For Blank Data Card: Insert card into slot. To format card, turn On power. Select Card from menu. Data card formats when unit enters Card mode.

  • Page 28: Section 9 − System Setup

    SECTION 9 − SYSTEM SETUP 9-1. 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. >Range * Welding power source minimum and maximum voltage values are always needed. Amperage values are required for pulse welding.

  • Page 29: Section 10 − Standard Pulse Welding Programs

    SECTION 10 − STANDARD PULSE WELDING PROGRAMS Note Apk = Peak Amperage, Vpk = Peak Voltage, Abk = Background Amperage, PPS = Pulses Per Second, PWms = Pulse Width (milliseconds). Four teach points were used for factory set programs. If selection is set for fifteen teach points, the remaining points are interpolations from the 4 taught points.

  • Page 30: Program 5 − Stainless

    10-5. Program 5 − Stainless Wire Size/Type: .035” Gas: Ar - He - CO / 40 CFH (19 L/m) IPM / MPM PWms COMMENTS 700 / 17.8 33.9 400 / 10.2 31.6 200 / 5.1 28.5 100 / 2.5 26.0 10-6.

  • Page 31: Section 11 − Setting Sharparce Control

    SECTION 11 − SETTING SharpArcE CONTROL 11-1. Selecting And Adjusting SharpArcE Control SharpArc is “Arc” on the display. It is used to adjust arc cone width and arc characteristics. Use front panel parameter select button to move > to select Arc. Use Display Control to adjust Arc setting.

  • Page 32: Section 12 − Teach Points

    SECTION 12 − TEACH POINTS 12-1. Teach Using 15 Points Apk = Peak Amperage Vpk = Peak Voltage Abk = Background Amperage PPS = Pulses Per Second IPM / MPM PWms = Pulse Width (Milliseconds) 780 / 19.8 750 / 19.1 700 / 17.8 650 / 16.5 600 / 15.2...

  • Page 33: Teach Using 4 Points

    12-2. Teach Using 4 Points Apk = Peak Amperage Vpk = Peak Voltage Abk = Background Amperage IPM / MPM PPS = Pulses Per Second 780 / 19.8 PWms = Pulse Width (Milliseconds) 750 / 19.1 700 / 17.8 650 / 16.5 600 / 15.2 550 / 14.0 500 / 12.7...

  • Page 34: Redefining Teach Points

    12-3. Redefining Teach Points IPM determines the weld metal deposition rate. Redefining IPM is not normally Redefining IPM Teach Point required unless special wire or unusual joint design is needed. Use front panel parameter select T r i m P r g button to move >...
  • Page 35 Date Program Number Wire Size/Type Flowrate CFH(L/min) Equipment Used − Power Source Serial Number Wire Feeder Serial Number Gun Model Weld Cable − Negative Positive Wire Manufacturer Mfg. Date IPM / MPM PWms COMMENTS Preflow Seconds: Run-In Trim/Volts: IPM / MPM: Seconds: Crater Volts: IPM / MPM:...

  • Page 36: Section 13 − Maintenance And Troubleshooting

    SECTION 13 − MAINTENANCE AND TROUBLESHOOTING 13-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Clean and Repair or tighten Replace replace weld unreadable cracked terminals. labels. weld cable. Replace Check Check gas Check gun cracked 14-pin cord. hose and cable.

  • Page 37: Error Displays

    13-2. 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 Release Trigger Error Display Press front panel Parameter Select to clear error.

  • Page 38: Troubleshooting

    13-3. Troubleshooting Y Disconnect power before troubleshooting Trouble Remedy 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 4-2 and 4-3). Wire feeder is on, meter(s) do not light Check and reset CB1 (see Section 5-4).
  • Page 39 Notes OM-1585 Page 35...

  • Page 40: Section 14 − Electrical Diagram

    SECTION 14 − ELECTRICAL DIAGRAM Figure 13-1. Circuit Diagram OM-1585 Page 36...
  • Page 41 SD-183 495-A OM-1585 Page 37...

  • Page 42: Section 15 − Parts List

    SECTION 15 − PARTS LIST Hardware is common and not available unless listed. Fig 14-2 Fig 14-3 ST-157 134-F Figure 14-1. Main Assembly OM-1585 Page 38...
  • Page 43 Item Part Description Quantity Figure 14-1. Main Assembly ....141 753 HUB & SPINDLE ASSEMBLY, (consisting of) ......
  • Page 44 Hardware is common and not available unless listed. See Table 14-1 For Drive Roll & Wire Guide Kits ST-137 222-K Figure 14-2. Drive Assembly, Wire OM-1585 Page 40...
  • Page 45 Item Dia. Part Mkgs. Description Quantity Figure 14-2. Drive Assembly, Wire (Fig 14-1 Item 22) ....010 668 SCREW, cap stl sch .250-20 x 1.500 .
  • Page 46 Hardware is common and not available unless listed. ST-157 135-G Figure 14-3. Control Box OM-1585 Page 42...
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 14-3. Control Box (Fig 14-1 Item 14) ....147 139 TAPE, adh acrylic double sided .010 x .500 x 3.000 .
  • Page 48 Item Dia. Part Mkgs. Description Quantity Figure 14-3. Control Box (Fig 14-1 Item 14) (Continued) ....159 264 RING, rtng ext .625 shaft grv x .045thk E style .
  • Page 49 Table 14-1. Drive Roll And Wire Guide Kits Wire Size V-GROOVE U-GROOVE VK-GROOVE UC-GROOVE 4 Roll Drive 4 Roll Drive 4 Roll Drive 4 Roll Drive Metric Fraction Roll Roll Roll Roll .023-.025 in. 0.6 mm 150 993 149 518 151 024 087 130 .030 in.
  • Page 50 Notes...
  • Page 51 Effective January 1, 1998 (Equipment with a serial number preface of “KJ” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions APT, ZIPCUT &...

  • Page 52: Options And Accessories

    Contact the Delivering Carrier for: 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.  PRINTED IN USA 1998 Miller Electric Mfg. Co. 9/98...

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