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Miller Electric SS-75D12 manual

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Table of contents for the manual

  • Page 1

    SS-75S12, SS-75S16, SS-75D12, and SS-75D16 OM-230 298A 2006 − 09 Processes Description MIG (GMA W) W elding Flux Cored (FCA W ) Welding (Gas-and Self-Shielding) Submerged (SAW) W elding Wire Feeder (Use with CV Power Sources) SS-75S/D Swingarc ™ V isit our website at www.MillerWelds.com File: MIG (GMA W)[...]

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

  • Page 3

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

  • Page 4

    [...]

  • Page 5

    OM-230 298 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 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 me[...]

  • Page 6

    OM-230 298 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching[...]

  • Page 7

    OM-230 298 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.[...]

  • Page 8

    OM-230 298 Page 4 1-5. Principal Safety Standards Safety i n W elding, 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 W elding and Cut- ting of Containers and Piping , American W elding Society Standard A [...]

  • Page 9

    OM-230 298 Pa ge 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les ut ilisés Sy mbole graphique d’avert iss ement ! Att ention ! Cette pro - cédur e comporte d es r i sques poss i[...]

  • Page 10

    OM-230 298 Page 6 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. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la pe[...]

  • Page 11

    OM-230 298 Pa ge 7 2-3 . Dange rs suppléme ntaire s en r e lation avec l’installa tion, le f onctionne ment et l a maintena nce 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[...]

  • Page 12

    OM-230 298 Page 8 2-5. Princi pales no rmes de sécurit é Safety in W elding, 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 fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W el[...]

  • Page 13

    OM-230 298 Page 9 SECTION 3 − INTRODUCTION 3-1. Specifications T ype of Input Power W elding Power Source T ype Maximum Spool W eight Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating W eight 24 V olts AC Single-Phase 10 Amperes 50/60 Hertz Constant V oltage (CV) DC With 14-Pin And Contactor Control 60 lb (27 kg) Standard: 50 T o [...]

  • Page 14

    OM-230 298 Page 10 4-2. Adjusting Control T ilt Bracket 803 155 1 T ilt Bracket 2 Rear Pivot Screw 3 Front Screw Loosen rear pivot screw. Remove front screw . Pivot control down- ward to desired viewing angle. Re- place and tighten front screw . T ight - en pivot screw . 1 2 3 4-3. Installing Boom And Reel Support ST-142 596-C 1 Swivel Plates 2 Y o[...]

  • Page 15

    OM-230 298 Page 1 1 4-4. Installing Wire Guide Extension ST-152 323 1 Wire Guide Fitting 2 Bolt 3 Monocoil Liner 4 Wire Guide Extension T ighten bolt to secure liner in wire guide fitting. Do not overtighten bolt and crush liner . 1 2 3 4 3/8 in T ools Needed: 804 726-A Y T urn Off wire feeder and welding power source. Stop engine on welding genera[...]

  • Page 16

    OM-230 298 Page 12 Ref. 803 019 1 Interconnecting Cable Receptacle 2 Interconnecting Cable 3 14-Pin Control Cable 4-6. Control Box Connections 1 2 3 4-7. 14-Pin Plug Information Pin* Pin Information A 24 volts ac with respect to socket G. B Contact closure to A completes 24 volts ac contactor control circuit. A J K G Circuit common for 24 volts ac [...]

  • Page 17

    OM-230 298 Page 13 4-8. Removing Safety Collar And Adjusting Boom 1 Locking Knob T ighten knob to prevent boom movement. Loosen knob to allow boom movement. Change knob po- sition to limit upward movement. Pull boom down slightly and remove safety collar . Boom should balance in any position from horizontal to 60 degrees above horizontal. If neces-[...]

  • Page 18

    OM-230 298 Page 14 1 2 4 3 4-1 1. Installing Drive Rolls 804 737-A 1 Drive Roll Carrier 2 Ejector Button 3 Drive Roll 4 Pressure Door Assembly Installation Open pressure door assembly . Lift drive roll swing arm. Align drive roll slots with three lobes on drive roll carrier . Insert drive roll onto carrier . Drive roll will snap into place. When cl[...]

  • Page 19

    OM-230 298 Page 15 4-12. Installing PD Continuous Wire Guides Ref. 804 731-A . PD Continuous Wire Guides: Should be used with .068/.072 in (1.8 mm) and smaller diameter wire for optimal performance. Should be used with PD drive rolls and cannot be used with non-PD (old- style) drive rolls. . 70 series wire guides are not compat- ible with 75 series[...]

  • Page 20

    OM-230 298 Page 16 4-13. Installing Non-PD (Old Style) Wire Guides Ref. 804 732-A 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. 1 PD Inlet Guide 2 Intermediate Guide 3 Guide Holder 4 Exit Guide 5 Set Screw 6 Pressure Door A[...]

  • Page 21

    OM-230 298 Page 17 4-14. Installing W elding Gun 804 730-A 1 Gun Locking T ab 2 Power Clamp Knob 3 Power Pin Groove 4 Gun Connection End Installing gun with Accu-Mate connec- tion 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 continuous guide (or exit guide i[...]

  • Page 22

    OM-230 298 Page 18 4-15. Installing Welding Wire And Adjusting Pressure Drive Setting Install wire spool. Ad - just tension nut so wire is taut when wire feed stops. NONCONDUCTIVE SURF ACE NONCONDUCTIVE SURF ACE No Wire Slip Wire Slips T ools Needed: 15/16 in Ref. 804 727-A 1 Adjust tension. 2 1 Drive Roll Pressure Adjustment Lever 2 Notch In Lever[...]

  • Page 23

    OM-230 298 Page 19 4-16. Setting Internal DIP Switches Position Settings And Results For DIP Switch S1 On PC1 Run-In feature is not avail- able. X - Means switch may be in either position. Run-In feature is available. X - Means switch may be in either position. . If 14 pin power cable from pow- er source does not provide volt- ag e and current feed[...]

  • Page 24

    OM-230 298 Page 20 T ools Needed: 1/4 in 4-17. Equipment DIP Switch Settings (For Models With Meters Only) 12 3 45 Inches/Minute Digital Meter DIP Switch Setting Ref. 803 154 Remove wrapper . 1 DIP Switch S2 On Digital Meter Board PC60 Install wrapper when finished. 12 3 45 Meters/Minute PC60 1 SECTION 5 − OPERA TION 5-1. Operational T erms The f[...]

  • Page 25

    OM-230 298 Page 21 5-2. Power Switch 1 Power Switch 1 803 153 5-3. Jog/Purge And T rigger Hold 1 803 152 3 1 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. If equippe[...]

  • Page 26

    OM-230 298 Page 22 5-4. V oltage Control And Digital Meters (For Models With Meters Only) 3 803 152 1 2 1 V oltmeter 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 contro[...]

  • Page 27

    OM-230 298 Page 23 SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. n = Check ~ = Clean l = Replace Reference Every 3 Months Section 4-5, 4-6 l Unreadable Labels ~ W eld T erminals nl W eld Cable nl Motor Brush Section 4-5, 4-6 n 14-Pin Cord n Gas Hose and Fittings n Gun Cable Every 6 Mon[...]

  • Page 28

    OM-230 298 Page 24 6-3. Diagnostics • Error Indications Error conditions are indicated by LED3 on PC 1 or on display (on models with meters). T o view LED3, turn Off unit, remove wrapper , an d turn unit On. LED3 is most easily observed from the left side of the unit. The LED blinks in a 2.5 second cycle. The number of blinks in this period indic[...]

  • Page 29

    OM-230 298 Page 25 6-4. T roubleshooting Y Disconnect power before troubleshooting T rouble Remedy Wire feeds, shielding gas flows, but electrode wire is not energized. Check interconnecting cord connections. If secure, check cord for continuity and repair or replace (see Sections 4-5 and 4-6 ) . Wire feeder is on, display does not light up, motor [...]

  • Page 30

    OM-230 298 Page 26 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram 202 246-C[...]

  • Page 31

    OM-230 298 Page 27 Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.weldin g .or g Star t Y our Pr ofessional W eldin g Career Now![...]

  • Page 32

    OM-230 298 Page 28 SECTION 8 − P ARTS LIST 804 725-A 1 2 3 4 5 6 7 8 7 10 11 12 13 31 9 Fig 8-2 Fig 8-3 Fig 8-5 2 14 15 18 22 23 24 25 26 27 Fig 8-4 18 29 30 . Hardware is common and not available unless listed. 16 17 20 19 21 28 Figure 8-1. Main Assembly[...]

  • Page 33

    OM-230 298 Page 29 Quantity Description Part No. Dia. Mkgs. Item No. Model 12 16 Figure 8-1. Main Assembly 1 See Note Control Box, (Figure 8-2) 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 201 319 Cable, Interconnecting (consisting of) 1 . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 34

    OM-230 298 Page 30 803 028-B . Hardware is common and not available unless listed. 2 12 14 15 16 19 20 23 26 17 22 1 3 4 5 6 7 8 9 10 11 9 8 13 24 25 21 18 27 Figure 8-2. Control Box Quantity Description Part No. Dia. Mkgs. Item No. Model 75S 75D Figure 8-2. Control Box (Figure 8-1 Item 1) 1 RC40 047 637 Housing Rcpt+Skts, (service kit) 1 1 . . . .[...]

  • Page 35

    OM-230 298 Page 31 Quantity Description Part No. Dia. Mkgs. Item No. Model 75S 75D Figure 8-2. Control Box (Figure 8-1 Item 1) (Continued) 10 070 371 Blank, Snap-In Nyl 1.125 Mtg Hole 2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 200 553 Bracket, Control Box Mounting 1 1 . . . . . . . . . [...]

  • Page 36

    OM-230 298 Page 32 804 729-A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 8 9 24 27 28 20 21 19 22 23 26 25 26 . Hardware is common and not available unless listed. Figure 8-3. Boom Assembly[...]

  • Page 37

    OM-230 298 Page 33 Quantity Description Part No. Item No. Model 12 16 Figure 8-3. Boom Assembly (Figure 8-1 Item 13) 1 000 527 Plug, 0.875 Inch 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 229 276 Boom, Single 12Ft 1 0 . . . . . . . . . . . . . . . . . . . . [...]

  • Page 38

    OM-230 298 Page 34 See T able 8-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 804 733-A 10 21 2 9 8 7 6 5 4 3 20 2 21 22 15 17 16 18 19 23 1 14 20 13 11 12 24 Figure 8-4. Drive Assembly , Wire Item No. Diagram marking Part No. Description Quantity Figure 8-4. Drive Assembly , Wire (Figure 8-1 Item 27) [...]

  • Page 39

    OM-230 298 Page 35 . Hardware is common and not available unless listed. 804 734-A 2 3 4 1 5 6 7 Figure 8-5. Drive Assembly With Motor Item No. Diagram marking Part No. Description Quantity Figure 8-5. Drive Assembly With Motor (Figure 8-1 Item 27) 1 223 252 T achometer , Optical Encoder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 40

    OM-230 298 Page 36 ST-146 339-B 1 2 3 4 5 6 7* 9 10 11 12 13 14 2 3 8 *Includes Item 8 . Hardware is common and not available unless listed. Figure 8-6. Support, Hub & Reel Description Part No. Item No. Quantity Figure 8-6. Support, Hub & Reel (Figure 8-1 Item 10) 1 142 399 Support, Reel 1 . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 41

    OM-230 298 Page 37 Wire Size PD-V for Hard Wire (1 kit or 4 rolls & 1 guide required) PD-U for Aluminum (1 kit or 4 rolls & 1 guide required) Guides for Old Style Drive Rolls (1 each required) Standard Drive Rolls ( 4 required) Fraction Metric PD-V Kit Roll Guide Roll Inlet Intermediate Exit V Groove U Groove VK Groove UC Groove .023 − .0[...]

  • Page 42

    OM-230 298 Page 38 Notes[...]

  • Page 43

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 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 expe[...]

  • Page 44

    PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 9 20-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters −[...]