Instruction/ maintenance manual of the product SS-75S16 Miller Electric
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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.
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 .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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.
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.
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 .
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.
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.
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.
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 .
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 Ratin.
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 .
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.
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.
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 .
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 ) .
OM-230 298 Page 26 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram 202 246-C.
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!.
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 .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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 .
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 .
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 .
OM-230 298 Page 38 Notes.
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.
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.
An important point after buying a device Miller Electric SS-75S16 (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 SS-75S16 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 SS-75S16 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric SS-75S16 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric SS-75S16 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric SS-75S16, 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 SS-75S16.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric SS-75S16. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric SS-75S16 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
