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OM-230 300A
2006 −09
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas-and Self-Shielding)
Submerged (SAW) Welding
Description
Wire Feeder
(Use with CV Power Sources)
™
DS-75S/D Swingarc
DS-75S12, DS-75S16, DS-75D12, and DS-75D16
File: MIG (GMAW)
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Insta
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 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 Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessa
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching HOT PART
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Have only qualified persons remove doors, Do not overload building wiring − be sure power supply system is panels, covers, or guards for main
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800 −463 −6727 or in Toronto 416 −747 −4044, website: www.csa −in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American Na
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. Ce groupe de symboles signifie Avertissement ! Attention ! Risques Indique un message de sécurité particulier d’É
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LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures Le rayonnement de l’arc du procédé de soudage ou même la mort. génère des rayons visibles et invisibles intenses Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation. quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien aérer l
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou S’abstenir de toucher des organes mobiles tels à proximité de surfaces inflammables. que des ventilateurs. Ne pas installer l’appareil à proximité de Maintenir fermés et verrouillés les portes, produits inflammables. panneaux, recouvrements et dispositifs de pro
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2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet : ternet : www.global.ihs.com). www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87
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SECTION 3 − INTRODUCTION 3-1. Specifications Type of Input Welding Power Wire Feed Speed Wire Diameter Welding Circuit Weight Power Source Type Range Range Rating .023 To 5/64 in (0.6 12 ft (3.7 m): 100 Volts, 24 Volts AC Constant Voltage (CV) To 2.0 mm) 207 lb (94 kg) 750 Amperes, 100% Standard: 50 To 1400 Single-Phase DC With 14-Pin that provides Duty Cycle ipm (1.3 To 35.6 mpm) 10 Amperes voltage and current feedback Max Spool Weight: 16 ft (4.9 m): 50/60 Hertz 60 lb (27 kg) 280 lb (127 kg) 1
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4-2. Installing Control Box And Adjusting Tilt 1 Weld Control 2 Bracket 3 Screw Bracket and screws are installed onto bottom of control at factory. 4 Swivel 1 Loosen screws. Place control on swivel and slide forward. Tighten screws. 5 2 5 Tilt Bracket 6 Rear Pivot Screw 6 7 Front Screw Loosen rear pivot screw. Remove front screw. Pivot control down- 4 ward to desired viewing angle. Re- place and tighten front screw. Tight- 7 en pivot screw. 3 Tools Needed: 3/8 in 803 182 4-3. Installing Boom And
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4-4. Installing Wire Guide Extension 1 Wire Guide Fitting 2 Bolt 3 Monocoil Liner 1 4 Wire Guide Extension Tighten bolt to secure liner in wire 4 guide fitting. Do not overtighten bolt and crush liner. 3 Repeat procedure for opposite 2 side. Tools Needed: 3/8 in ST-152 383 4-5. Installing Guard 1 Motor Mounting Bracket 2 Mounting Screws Remove 4-screws from motor mounting bracket. 3 Guard Secure guard using 4 screws pre- viously removed. For standard speed motor mount guard use mounting holes as
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4-6. Equipment Connection Diagram Turn Off wire feeder and welding power source. Stop engine on welding generator. Use only with CC/CV DC Power Sources. 1 Constant Current (CC) or Constant Voltage (CV) Welding Power Supply 2 Remote 14 Connection 13 3 Ground Cable To Workpiece 1 4 Weld Cable To Feeder Weld cable and ground cable con- nections to power source (DCEN/ 2 DCEP) are dependant on wire type. 5 Workpiece 6 Weld Control 7 Boom 8 Trigger Connection 9 Gun 10 Swivel 3 11 Pipe Post And Bas
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4-7. Control Box Connections 1 Interconnecting Cables 2 Interconnecting Cable Receptacles 3 14-Pin Cord 1 2 3 Ref. 803 187 4-8. 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. J J A A K K I B G Circuit common for 24 volts ac circuit. L L H N C C +10 volts dc input from power source to wire feeder with respect to socket D. M M G G D D D Remote control circuit common. F F E E E 0 to +10 vol
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4-9. Removing Safety Collar And Adjusting Boom 1 Locking Knob Tighten knob to prevent boom movement. Loosen knob to allow boom movement. Change knob po- sition to limit upward movement. Pull boom down slightly and re- move safety collar. Boom should 4 balance in any position from hori- zontal to 60 degrees above hori- zontal. If necessary, adjust boom as follows: 2 Threaded Rod 3 Jam Nut Loosen jam nut and turn threaded rod until boom balances. Tighten 5 jam nut. Be sure several full threads are
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4-12. Installing Drive Rolls 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 closing swing arm, push firm- ly into position. Swing arm has built in resistance to prevent swing arm from closing abruptly. When using cored welding wire use knurled drive rolls. Removal
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4-13. Installing PD Continuous Wire Guides 3 1 2 4 Ref. 804 731-A 2 PD Wire Guide (Hard Wire) Remove PD inlet guide. PD Continuous Wire Guides: 3 PD Inlet Guide Insert wire guide gun end (indicated with ar- Should be used with .068/.072 in row) into block near brass power pin gun (1.8 mm) and smaller diameter wire for 4 Pressure Door Assembly connector. optimal performance. Installing PD continuous wire guides Should be used with PD drive rolls Install PD inlet guide. with PD drive rolls. and
