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Miller Electric D-64 manual

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Table of contents for the manual

  • Page 1

    Visit our website at www.MillerWelds.com Processes Descrip tio n MIG (GMAW) Flux Cored (FCAW) (Gas- and Self-Shielded) Submerged (SAW) Wire Feeder (Use with CV Power Sources) OM -1582 138 593X September 2001 D-64[...]

  • Page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 4

    dec_con 1 1/96 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Note Manufacturer ’ s Name: Miller Electric Mfg. Co. Manufacturer ’ s Address: 1635 W . Spencer Street Appleton, WI 54914 USA Declares that the product: D-64 conforms to the follo[...]

  • Page 5

    OM-1582 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch 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. This group of symbols means W arning! Wat[...]

  • Page 6

    OM-1582 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly of f from the weld. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z[...]

  • Page 7

    OM-1582 Page 3 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. F [...]

  • Page 8

    OM-1582 Page 4 1-5. EMF Information Considerations About W elding And The Ef fects Of Low Frequency Electric A n d M a g netic Fields W elding 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[...]

  • Page 9

    OM-1582 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulier .[...]

  • Page 10

    OM-1582 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dans l[...]

  • Page 11

    OM-1582 Page 7 1-3. Dangers suppl é mentaires 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- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharger [...]

  • Page 12

    OM-1582 Page 8 1-4. Principales normes de s é curit é Safety in W elding 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 Of fice, W ashington, D.C. 20402. Recommended Safe Practice for th[...]

  • Page 13

    OM-1582 Page 9 SECTION 2 – DEFINITIONS 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 56 + 2.3 S-178 936 A. W arning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. W elding wire and drive parts are at welding voltage during operation – keep hands and metal objects clear . 1 Electric shoc[...]

  • Page 14

    OM-1582 Page 10 ST-178 794-A 50/60 S/N: 24 10.0 Hz 50/60 IP 21 V 100 A 750 X 100 % V U 1 = A I 1 = 1 U 2 = I 2 = 2-2. Rating Label For CE Products For label location see Section 4-4. 2-3. Symbols And Definitions Some symbols are found only on CE products. Note A Amperes V V olts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz U 1 [...]

  • Page 15

    OM-1582 Page 1 1 SECTION 3 – INTRODUCTION 3-1. Specifications T y pe of Input Power W elding Power Source T y pe Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating IP Rating Overall Dimensions W eight 24 V olts AC Single-Phase 10 Amperes 50/60 Hertz Constant V oltage (CV) DC With 14-Pin And Contactor Control Standard: 50 T o 780 ip[...]

  • Page 16

    OM-1582 Page 12 4-2. Gun Recommendation T able Process Gun GMA W – Hard or Cored Wires Roughneck C-Series Guns: 300, 400, 500, And 600 Amp. FCA W – Self-Shielding Wires FC-1260 Or FC-1 1 50 4-3. Equipment Connection Diagrams 1 W elding Power Source 2 Contactor Control/Power Cord 3 Positive (+) Weld Cable 4 Negative ( – ) W eld Cable 5 W orkpi[...]

  • Page 17

    OM-1582 Page 13 Ref. 800 353-B T ools Nee d e d : 4-4. Rear Panel Connections 1 ” Y ” Adapter Gas Hose (Supplied) 2 Shielding Gas V alve Fitting Requires fitting with 5/8-18 right- hand threads. 3 Weld Cable T erminal 4 Jumper Weld Cable 5 Weld Cable 6 Optional Current Sensor Connections 7 14-Pin Cord 8 Power Switch 9 Rating Label Location 9/16[...]

  • Page 18

    OM-1582 Page 14 4-6. Wire T ype, Size, And Feed Speed Capability T able Motor Speed Wire T ype Wire Size Feed Speed Capability Standard All .023 T o 5/64 in (0.6 T o 2 mm) 50 T o 780 ipm (1.3 T o 19.8 mpm) Standard All 3/32 T o 7/64 in (2.4 T o 2.8 mm) 50 T o 700 ipm (1.3 T o 17.8 mpm) Standard All 1/8 in (3.2 mm) 50 T o 300 ipm (1.3 T o 7.6 mpm) O[...]

  • Page 19

    OM-1582 Page 15 3 Ref. 143 259-G / Ref. ST-153 093-A T ools Nee d e d : 4-8. Rotating The Drive Assembly Remove screws (6) from front edge of wrapper , and loosen screws on back edge of wrapper . 1 Front Panel 2 Drive Assembly Rotation Adjustment Opening 3 Drive Assembly 3/16 in 1/4 in 1 2[...]

  • Page 20

    OM-1582 Page 16 4-9. Installing And Threading W elding 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. Lay gun cable out straight. Cut of f end of wire. Push wire through guides [...]

  • Page 21

    OM-1582 Page 17 Ref. 143 259-G / Ref. SA-146 866-B / Ref. SA-148 666-E / Ref. SA-150 588-D T ools Nee d e d : . If wire feeder is equipped with a voltage sensing lead, set DIP switch S3 to the OFF position (up). If wire feeder is NOT equipped with a voltage sensing lead, set DIP switch S3 to the ON position (down). 12 OFF 1 2 OFF 12 OFF 12 Or Long [...]

  • Page 22

    OM-1582 Page 18 SECTION 5 – OPERA TION 5-1. Front Panel Controls 1 V oltmeter (Optional) (See Section 4-10) 2 Wire Speed Meter (Optional) Factory set to display inches per minute. If display of meters per minute is desired, see Section 4-10. 3 Schedule A Wire Speed Control The scale is calibrated in inches per minute x 100 and meter per minute. 4[...]

  • Page 23

    OM-1582 Page 19 802 433-A 5-2. Overload Protection And Optional Side Panel Controls 1 Circuit Breaker CB1 CB1 protects wire feed motor from overload. Press to reset. 2 Preflow Control Control sets time gas flows before welding wire is energized. 3 Spot Time Control Factory set for 0 to 5 seconds of spot time. If 0 to 2.5 seconds is desired, see Sec[...]

  • Page 24

    OM-1582 Page 20 6-2. T roubleshooting Y Disconnect power before troubleshooting T rouble Remedy Wire feeds, shielding gas flows, but elec- trode wire is not energized. Check in terconnecting cord connections. If secure, check cord for continuity and repair or replace (see Sections 4-3 and 4-4). Wire feeder is on, meter(s) do not light up, motor doe[...]

  • Page 25

    OM-1582 Page 21 Notes[...]

  • Page 26

    OM-1582 Page 22 SECTION 7 – ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram[...]

  • Page 27

    OM-1582 Page 23 197 518 – A[...]

  • Page 28

    OM-1582 Page 24 SECTION 8 – P ARTS LIST 1 2 3 4 5 6 7 8 7 6 5 9 10 11 12 30 29 28 27 . Hardware is common and not available unless listed. 143 225-K 13 15 16 17 18 19 20 21 22 23 24 25 26 Fig 8-2 14 Fig 8-5 Fig 8-5 Figure 8-1. Main Assembly[...]

  • Page 29

    OM-1582 Page 25 Description Part No. Item No. Quantity Figure 8-1. Main Assembly 1 143 160 HUB & SPINDLE ASSEMBL Y , (consisting of) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 058 427 RING, retaining spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 30

    OM-1582 Page 26 143 226-G 1 2 3 5 6 7 10 11 12 13 14 15 16 17 18 19 20 21 22 Fig 8-3 10 Fig 8-4 8 9 . Hardware is common and not available unless listed. 4 Figure 8-2. Control Box[...]

  • Page 31

    OM-1582 Page 27 Description Part No. Dia. Mkgs. Item No. Quantity Figure 8-2. Control Box (Fig 8-1 Item 26) 1 139 235 P ANEL, side lower LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fig 8-4 CONTROL P ANEL 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 32

    OM-1582 Page 28 Description Part No. Dia. Mkgs. Item No. Quantity Figure 8-2. Control Box (Fig 8-1 Item 26) (Continued) 1 19 951 BLANK, snap-in nyl .437mtg hole 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 983 BLANK, snap-in nyl .500mtg hole 2 . . . . . . . . . . . . . . . .[...]

  • Page 33

    OM-1582 Page 29 Description Part No. Dia. Mkgs. Item No. Quantity Figure 8-3. Panel, Front w/Components (Fig 8-2 Item 21) 1 R1,2 073 562 POTENTIOMETER, C sltd sft 1/T 2W 10K ohm . . . . . . . . . . . . . . . . . . (Wire Feed Speed A) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 149 654 P ANEL, front 1 . . . . [...]

  • Page 34

    OM-1582 Page 30 146 340-B 1 2 3 10 6 7 8 5 . Hardware is common and not available unless listed. 9 4 11 Figure 8-4. Control Panel Description Part No. Dia. Mkgs. Item No. Quantity Figure 8-4. Control Panel (Fig 8-2 Item 2) 1 S31,32 ♦ 01 1 770 SWITCH, tgl SPDT 6A 125V AC (T rigger Hold/Spot) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 35

    OM-1582 Page 31 Description Part No. Dia. Mkgs. Item No. Quantity Figure 8-4. Control Panel (Fig 8-2 Item 2) (Continued) 10 PC80 196 746 CIRCUIT CARD, run-in control 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 093 551 KNOB, .125dia shaft w/.125 set screw 1 . . . . . . . . . . . . . . . . . .[...]

  • Page 36

    OM-1582 Page 32 Description Part No. Dia. Mkgs. Item No. Figure 8-5. Drive Assembly , Wire (Fig 8-1 Items 15 & 25) Quantity 2 Drive Roll 4 Drive Roll 1 010 668 SCREW, cap stl sch .250-20 x 1.500 2 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 172 075 CARRIER, drive roll w/components 2 4 . . [...]

  • Page 37

    OM-1582 Page 33 .023-.025 in. 0.6 mm 151 030 151 024 087 130 .030 in. 0.8 mm 151 031 151 025 053 695 .035 in. 0.9 mm 151 032 151 026 053 700 151 044 151 036 072 000 151 061 151 052 132 958 .045 in. 1.1/1.2 mm 151 033 151 027 053 697 151 045 151 037 053 701 151 062 151 053 132 957 151 077 151 070 083 489 .052 in. 1.3/1.4 mm 151 034 151 028 053 698 1[...]

  • Page 38

    OM-1582 Page 34 Notes[...]

  • Page 39

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

  • Page 40

    PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 West S pencer Street Applet on, WI 5 4914 US A International He adquarte rs – USA USA Phone: 920-735-4505 Auto-At t ended USA & Canada FAX: 920-735-4134 Int ernati onal F AX: 9 20-735-4125 European Headqua rters – United[...]