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OM-1582 138 593X
September 2001
Processes
MIG (GMAW)
Flux Cored (FCAW)
(Gas- and Self-Shielded)
Submerged (SAW)
Description
Wire Feeder
(Use with CV Power Sources)
D-64
Visit our website at
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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 Installation, Operation, and Maintenance . . . . . . .
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Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Note Manufacturer’s Name: Miller Electric Mfg. Co. Manufacturer’s Address: 1635 W. Spencer Street Appleton, WI 54914 USA Declares that the product: D-64 conforms to the following Directives and Standards: Directives Low Voltage Directive: 73/23/EEC Electromagnetic Compatibility (EMC) Directive: 89/336/EEC Machinery Directives: 89/392/EEC, 91/368/
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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 necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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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 a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 li
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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. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body. years of resea
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 – DEFINITIONS 2-1. 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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2-2. Rating Label For CE Products For label location see Section 4-4. S/N: U 24 V 1 50/60 Hz 1 50/60 = IP 21 I = 10.0A 1 U 100 V I = 750 A X 100 % 2 2 = ST-178 794-A 2-3. Symbols And Definitions Some symbols are found only on CE products. Note Amperes Volts Alternating Current Duty Cycle A V X Degree Of Hertz Primary Voltage Wire Feed U Protection IP Hz 1 Jog Output Trigger Line Connection Press To Set Load Voltage Trigger Hold On Trigger Hold Off U 2 Purge Spot Weld Time Spot Weld Continuous W
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SECTION 3 – INTRODUCTION 3-1. Specifications Welding Type of Input Welding Power Wire Feed Wire Diameter IP Overall Circuit Weight Power Source Type Speed Range Range Rating Dimensions Rating Standard: 50 To Length: 32 in 100 Volts, 780 ipm (1.3 To .023 To 1/8 in (812 mm) 750 24 Volts AC 19.8 mpm) (0.6 To 3.2 mm) Constant Voltage (CV) Amperes, Single-Phase Width: 18 in 78 lb DC With 14-Pin And IP 23 100% Duty 10 Amperes Optional High Max Spool (457 mm) (35 kg) Contactor Control Cycle 50/60 Hert
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4-2. Gun Recommendation Table Process Gun GMAW – Hard or Cored Wires Roughneck C-Series Guns: 300, 400, 500, And 600 Amp. FCAW – Self-Shielding Wires FC-1260 Or FC-1150 4-3. Equipment Connection Diagrams 1 Welding Power Source 2 Contactor Control/Power Cord 3 Positive (+) Weld Cable 4 Negative (–) Weld Cable 1 5 Workpiece 6 Gun 2 7 Wire Feeder 10 8 PSA-2 Control (Optional) Use with welding power sources supplying 115 volts ac power. 3 9 Gas Hose 10 Gas Cylinder 4 5 9 6 7 1 10 2 3 4 5 9 8 6 7 152
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4-4. Rear Panel Connections 1 ”Y” Adapter Gas Hose (Supplied) 2 Shielding Gas Valve Fitting Requires fitting with 5/8-18 right- 6 hand threads. 6 78 9 3 Weld Cable Terminal 4 Jumper Weld Cable 5 Weld Cable 6 Optional Current Sensor Connections 7 14-Pin Cord 8 Power Switch 9 Rating Label Location 1 4 2 5 3 4 5 Tools Needed: 9/16, 5/8 in 3/16 in Ref. 800 353-B 4-5. 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 cont
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4-6. Wire Type, Size, And Feed Speed Capability Table Motor Speed Wire Type Wire Size Feed Speed Capability Standard All .023 To 5/64 in (0.6 To 2 mm) 50 To 780 ipm (1.3 To 19.8 mpm) Standard All 3/32 To 7/64 in (2.4 To 2.8 mm) 50 To 700 ipm (1.3 To 17.8 mpm) Standard All 1/8 in (3.2 mm) 50 To 300 ipm (1.3 To 7.6 mpm) Optional High All .023 To 5/64 in (0.6 To 2 mm) 92 To 1440 ipm (2.3 To 35.6 mpm) Speed 4-7. Motor Start Control To change wire feed starting speed, proceed as follows: Turn Off wir
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4-8. Rotating The Drive Assembly Remove screws (6) from front edge of wrapper, and loosen screws on back edge of wrapper. 1 Front Panel 2 Drive Assembly Rotation Adjustment Opening 3 Drive Assembly 2 1 3 Tools Needed: 1/4 in 3/16 in Ref. 143 259-G / Ref. ST-153 093-A OM-1582 Page 15
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4-9. Installing And Threading Welding Wire about 2 in (51 mm) from nonconductive Be sure that outlet cable has proper size For soft wire or small diameter stainless surface and press gun trigger to feed wire liner for the welding wire size. When steel wire, use 2 drive rolls and set drive against surface. Tighten knob so wire does installing gun, position liner extending roll pressure from 0 to a maximum of 4 not slip. Do not overtighten. If contact tip is from outlet wire guide as close as
