Instruction/ maintenance manual of the product S-75D Miller Electric
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Visit our website at www.MillerWelds.com S-75S, S-75D Processes Description MIG (GMA W) W elding Flux Cored (FCA W ) Welding (Gas- And Self-Shielded) Wire Feeder OM-223 605A May 2005.
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 .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-223 605 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.
OM-223 605 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
OM-223 605 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.
OM-223 605 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 .
OM-223 605 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.
OM-223 605 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.
OM-223 605 Pa ge 7 2-3 . Dangers s upplé mentaire s e n rela t i on a v ec l’installa tion, l e fonctionneme nt e t la maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables.
OM-223 605 Page 8 2-5. Princi pales n ormes de sécu rité 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 .
OM-223 605 Page 9 SECTION 3 − 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 .
OM-223 605 Page 10 3-2. 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 Program Wire Feed .
OM-223 605 Page 1 1 SECTION 4 − INTRODUCTION 4-1. Specifications T ype of Input Power W elding Power Source T ype W elding Circuit Rating IP Rating Overall Dimensions Maximum Spool W eight Wire Feed.
OM-223 605 Page 12 5-2. Rear Panel Connections And Rotating Drive Assembly Ref. 804 183-A / 804 184-A 2 4 1 14-Pin Control Cable - 10 ft (3.0 m) 2 Shielding Gas V alve Fitting Connect customer-supplied gas hose with 5/8-18 right-hand threads. . Shielding gas pressure not to exceed 90 PSI (620 kPa).
OM-223 605 Page 13 5-3. 14-Pin Plug PLG12 Information Pin* Pin Information A 24 volts ac with respect to socket G. A J K B Contact closure to A completes 24 volts ac contactor control circuit. A J B K I L G Circuit common for 24 volts ac circuit. C L N H D M G C +10 volts dc input from power source to wire feeder with respect to socket D.
OM-223 605 Page 14 5-7. Installing PD Continuous Wire Guides Ref. 804 192 / 804 188-A . PD Continuos 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.
OM-223 605 Page 15 5-8. Installing Non-PD (Old Style) Wire Guides Ref. 804 192 / 804 188-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.
OM-223 605 Page 16 5-9. Installing Welding Gun 804 189-A 1 Power Clamp Knob 2 Gun Locking T ab 3 Power Pin Groove 4 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.
OM-223 605 Page 17 5-10. Installing W elding Wire And Adjusting Pressure Drive Setting Ref. 804 190-A T ools Needed: 1 Drive Roll Pressure Adjustment Lever 2 Notch In Lever (Indicates Pressure Settings) Pressure drive settings range from 1 to 9 with 9 being the maximum setting.
OM-223 605 Page 18 5-1 1. 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.
OM-223 605 Page 19 T ools Needed: 1/4 in 5-12. Equipment DIP Switch Settings (For Models With Meters Only) 12 3 45 Factory Default Inches/Minute Digital Meter DIP Switch Setting Ref.
OM-223 605 Page 20 SECTION 6 − OPERA TION 6-1. Power Switch 1 Power Switch 804 182-A 1 6-2. Jog/Purge And T rigger Hold 1 802 828-A 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.
OM-223 605 Page 21 6-3. V oltage Control And Digital Meters (For Models With Meters Only) 3 804 182-A 1 2 1 V oltmeter The voltmeter displays actual or preset voltage from the welding power source through the 14 − pin control cable. 2 Wire Speed Meter Th e wire speed meter is factory set to display inches per minute.
OM-223 605 Page 22 7-2. 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.
OM-223 605 Page 23 7-3. T roubleshooting Y Disconnect power before troubleshooting T rouble Remedy Wire feeds, shielding gas flows, but electrode wire is not energized. Check cable connections. Check cables for continuity , and repair or replace cables if necessary (see Section 5-2).
OM-223 605 Page 24 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram 202 246-B.
OM-223 605 Page 25 Notes.
OM-223 605 Page 26 SECTION 9 − P ARTS LIST 804 185-A . Hardware is common and not available unless listed. Fig 9-2 Fig 9-3, 9-4 21 20 19 18 5 17 16 15 14 13 10 11 12 11 10 9 8 7 6 4 3 2 1 22 Figure 9-1.
OM-223 605 Page 27 Item No. Item No. Part No. Description Quantity Figure 9-1. Main Assembly Part No. Description Quantity 1 159 647 Insulator , Motor Clamp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-223 605 Page 28 802 945-D . Hardware is common and not available unless listed. 2 5 6 7 8 9 8 7 10 11 12 13 14 15 16 17 18 19 20 23 24 25 26 27 22 28 4 21 3 1 29 Figure 9-2. Control Box Item No. S-75S S-75D Figure 9-2. Control Box (Figure 9-1 Item 21) Diagram marking Part No.
OM-223 605 Page 29 Item No. Diagram marking Part No. Description Quantity Model S-75S S-75D Figure 9-2. Control Box (Figure 9-1 Item 21) 21 213 134 Knob, Encoder 1.670 Dia X .250 Id Push On W/Spring 0 1 . . . . . . . . . . . . . . . . . . . . . . . . .
OM-223 605 Page 30 See T able 9-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 804 186-A 4 5 6 7 8 3 2 1 9 10 2 11 12 13 14 15 16 17 18 19 20 21 22 Figure 9-3. Drive Assembly , Wire Item No. Item No. Part No.
OM-223 605 Page 31 . Hardware is common and not available unless listed. 804 191-A 1 2 3 4 5 6 Figure 9-4. Drive Assembly With Motor Item No. Diagram marking Part No. Description Quantity Model S-75S S-75D Figure 9-4. Drive Assembly , Wire (Figure 9-1 Item 4) 1 079 626 Screw, 010 − 32x .
OM-223 605 Page 32 Wire Size PD for Hard Wire (1 kit or 4 rolls & 1 guide required) PD 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 Kit Roll Guide Roll Inlet Intermediate Exit V Groove U Groove VK Groove UC Groove .
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!.
Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 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 .
PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05 Miller Elect ric Mf g. Co. An Illinois T ool Wo rks Co mpany 1635 W es t Spencer St reet Applet on, WI 5 4914 USA International He adquarters − U.
An important point after buying a device Miller Electric S-75D (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric S-75D yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric S-75D - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric S-75D you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric S-75D will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric S-75D, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric S-75D.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric S-75D. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric S-75D along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
