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OM-223 605A
May 2005
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
S-75S, S-75D
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 − DEFINITIONS 3-1. Warning Label Definitions A. Warning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. AB C C. Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects clear. 1 Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric shock by insulating yourself 1 1.1 1.2 1.3 from work
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3-2. Symbols And Definitions Some symbols are found only on CE products. Note Amperes Volts Alternating Current Duty Cycle A V X Degree Of Hertz Program Wire Feed Protection IP Hz Jog Output Trigger Line Connection Set Up Sequence Trigger Hold On Trigger Hold Off Purge Press To Set Start Crater Time Preflow Time Postflow Time Read Instructions Increase Primary Current Rated Current Load Voltage I I U 1 2 2 A Primary Voltage Dual Schedule U 1 B Notes OM-223 605 Page 10
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SECTION 4 − INTRODUCTION 4-1. Specifications Welding Wire Type of Input Welding Power IP Overall Maximum Wire Feed Circuit Diameter Weight Power Source Type Rating Dimensions Spool Weight Speed Range Rating Range 24 Volts ac Constant 100 Volts, IP 21 Length: 27 in 60 lb Standard .023 to 5/64 in 43 lb Single-Phase Voltage (CV) 750 Amperes, (686 mm) (27 kg) Speed: 50 to (0.6 to 2.0 (19.5 kg) 10 Amperes DC With 14-Pin, 100% Duty Width: 12-1/2 in 1400 ipm (1.3 mm) 50/60 Hertz that Provides Cycle (31
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5-2. Rear Panel Connections And Rotating Drive Assembly 1 14-Pin Control Cable - 10 ft (3.0 m) 2 Shielding Gas Valve Fitting Connect customer-supplied gas hose with 5/8-18 right-hand threads. Shielding gas pressure not to exceed 90 PSI (620 kPa). 3 Weld Cable 4 Weld Cable Screw - Screw Size (.375 − 16 X 1.50) Note two weld cable connec- tions: 0 to 350 Amps, and 350 Amps and above. 5 Drive Assembly 6 Drive Assembly Rotation Knob To rotate the drive assembly, loos- en drive assembly rotation
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5-3. 14-Pin Plug PLG12 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 volts dc output signal from wire feeder to power source with respect to socket D. H Voltage feedback; 0 to +10 volts dc,
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5-7. Installing PD Continuous Wire Guides 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. 70 series wire guides are not compatible with 75 series wire 3 feeders. 1 Pressure Assembly Door 2 PD Inlet Guide 3 PD Wire Guide (Hard Wire) 4 PD Wire Guide (Two Pieces interlocked for Aluminum 4 Wire) Installing PD continuous wire guides wi
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5-8. Installing Non-PD (Old Style) Wire Guides 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 Pressure Assembly Door 2 PD Inlet Guide 3 Intermediate Guide 4 Guide Holder 5 Exit Guide 4 Open pressure assembly door. 2 Lift up drive roll swing arms. 5 Install PD inlet guide. 3 Do not tighten set screw to se- cure inlet guide. Set screw may be used to se- cure PD inlet
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5-9. Installing Welding Gun 1 Power Clamp Knob 2 Gun Locking Tab 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. When installing gun, the liner should extend into the PD continu- ous guide (or exit guide if used) as far as possible without interfering with the guide. Align the groove in the power pin of the gun with the gun locking tab. Secure gun by tightening power 4 clamp knob. In
