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Manual Miller Electric DS-75D12

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  • Miller Electric DS-75D12 - page 1

    DS-75S12, DS-75S16, DS-75D12, and DS-75D16 OM-230 300A 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) DS-75S/D Swingarc ™ File: MIG (GMA W) V isit our website at www.MillerWelds.com ...

  • Miller Electric DS-75D12 - page 2

    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 .Mille ...

  • Miller Electric DS-75D12 - page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . ...

  • Miller Electric DS-75D12 - page 4

    ...

  • Miller Electric DS-75D12 - page 5

    OM-230 300 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. Y Marks a special safety me ...

  • Miller Electric DS-75D12 - page 6

    OM-230 300 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching ...

  • Miller Electric DS-75D12 - page 7

    OM-230 300 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. ...

  • Miller Electric DS-75D12 - page 8

    OM-230 300 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 .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American W elding Society Standard A ...

  • Miller Electric DS-75D12 - page 9

    OM-230 300 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. 2-1. Symbo les ut ilisés Sy mbole graphique d’aver tiss ement ! Att ention ! Cett e pro - cédur e comporte d es risques poss ib ...

  • Miller Electric DS-75D12 - page 10

    OM-230 300 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. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la pe ...

  • Miller Electric DS-75D12 - page 11

    OM-230 300 Pa ge 7 2-3 . Da ngers suppléme ntaires en r el ation avec l’ins tallation, le f onctionnem ent 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. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger ...

  • Miller Electric DS-75D12 - page 12

    OM-230 300 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 .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W el ...

  • Miller Electric DS-75D12 - page 13

    OM-230 300 Page 9 SECTION 3 − INTRODUCTION 3-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating W eight 24 V olts AC Single-Phase 10 Amperes 50/60 Hertz Constant V oltage (CV) DC With 14-Pin that provides voltage and current feedback Standard: 50 T o 1400 ipm (1.3 T ...

  • Miller Electric DS-75D12 - page 14

    OM-230 300 Page 10 4-2. Installing Control Box And Adjusting T ilt 1 W e ld Control 2 Bracket 3 Screw Bracket and screws are installed onto bottom of control at factory . 4 Swivel Loosen screws. Place control on swivel and slide forward. Tighten screws. 5 T ilt Bracket 6 Rear Pivot Screw 7 Front Screw Loosen rear pivot screw. Remove front screw . P ...

  • Miller Electric DS-75D12 - page 15

    OM-230 300 Page 1 1 4-4. Installing Wire Guide Extension ST-152 383 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 . Repeat procedure for opposite side. T ools Needed: 1 2 3 4 3/8 in 4-5. Installing Guard 804 783-A 1 Motor Mounting Brac ...

  • Miller Electric DS-75D12 - page 16

    OM-230 300 Page 12 804 784-A Y T urn Off wire feeder and welding power source. Stop engine on welding generator . Y Use only with CC/CV DC Power Sources. 1 Constant Current (CC) or Constant V oltage (CV) W elding Power Supply 2 Remote 14 Connection 3 Ground Cable T o W orkpiece 4 Weld Cable T o Feeder W eld cable and ground cable con- nections to p ...

  • Miller Electric DS-75D12 - page 17

    OM-230 300 Page 13 Ref. 803 187 1 Interconnecting Cables 2 Interconnecting Cable Receptacles 3 14-Pin Cord 4-7. Control Box Connections 1 3 2 4-8. 14-Pin Plug 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 volt ...

  • Miller Electric DS-75D12 - page 18

    OM-230 300 Page 14 4-9. Removing Safety Collar And Adjusting Boom ST-142 599-C 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 re- move safety collar . Boom should balance in any position from hori- zontal to 60 degrees above hori ...

  • Miller Electric DS-75D12 - page 19

    OM-230 300 Page 15 1 2 4 3 4-12. 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 . Insert drive roll onto carrier . Drive roll will snap into place. When clo ...

  • Miller Electric DS-75D12 - page 20

    OM-230 300 Page 16 4-13. 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. . 70 series wire guides are not compat- ible with 75 series ...

  • Miller Electric DS-75D12 - page 21

    OM-230 300 Page 17 4-14. 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. 1 PD Inlet Guide 2 Intermediate Guide 3 Guide Holder 4 Exit Guide 5 Set Screw 6 Pressure Door A ...

  • Miller Electric DS-75D12 - page 22

    OM-230 300 Page 18 4-15. 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. When installing gun, the liner should extend into the PD continuous guide (or exit guide i ...

  • Miller Electric DS-75D12 - page 23

    OM-230 300 Page 19 4-16. Installing Welding Wire And Adjusting Pressure Drive Setting NONCONDUCTIVE SURF ACE NONCONDUCTIVE SURF ACE No Wire Slip Wire Slips T ools Needed: 15/16 in Ref. 804 727-A 1 Adjust tension. 2 1 Drive Roll Pressure Adjustment Lever 2 Notch In Lever (Indicates Pressure Settings) Pressure drive settings range fr om 1 t o 8 with ...

  • Miller Electric DS-75D12 - page 24

    OM-230 300 Page 20 4-17. Setting Internal DIP Switches On Motor Boards Remove wrapper . 1 DIP Switch S1 On Motor Boards PC1 and PC101. S1-1 Run-In enable or disable. S1-2 Automatic Run-In versus Manual Adjustment Run-in. Install wrapper when finished. 803 063 / Ref. 802 944 Left Side Motor Control Board PC101 Right Side Motor Control Board PC1 Posi ...

  • Miller Electric DS-75D12 - page 25

    OM-230 300 Page 21 T ools Needed: 1/4 in 4-18. Equipment DIP Switch Settings (For Models With Meters Only) Ref. 803 154 / 803 188 Remove wrapper . 1 DIP Switch S2 On Digital Meter Board PC60 Install wrapper when finished. 123 45 Inches/Minute Digital Meter DIP Switch Setting 12 3 45 Meters/Minute PC60 1 ...

  • Miller Electric DS-75D12 - page 26

    OM-230 300 Page 22 SECTION 5 − OPERA TION 5-1. Power Switch 1 Power Switch 1 Ref. 803 183 1 Left/Right Select Switch Pressing the Left/Right Select switch allows the operator to choose which side of the unit’ s con- trols will operate. 5-2. Left/Right Select Switch 1 Ref. 803 184 5-3. Jog/Purge 1 Ref. 803 184 2 1 Jog/Purge Push Buttons 2 Wire S ...

  • Miller Electric DS-75D12 - page 27

    OM-230 300 Page 23 5-4. T rigger Hold Switch 1 T rigger Hold Switches T rigger hold allows the operator to weld without holding the gun trigger . • T o use the trigger hold function, place the trigger hold switch in the On position. • The operator must hold the trig- ger for a minimum of 2 seconds, bu t not longer than 6 seconds be- fore releas ...

  • Miller Electric DS-75D12 - page 28

    OM-230 300 Page 24 SECTION 6 − MAINTENANCE 6-1. Routine Maintenance Y Disconnect power before maintaining. n = Check ~ = Clean l = Replace Reference Every 3 Months Section 4-6, 4-7 l Unreadable Labels ~ W eld T erminals nl W eld Cable nl Motor Brush Section 4-6, 4-7 n 14-Pin Cord n Gas Hose and Fittings n Gun Cable Every 6 Months Or Section 4-12 ...

  • Miller Electric DS-75D12 - page 29

    OM-230 300 Page 25 6-3. Diagnostics 803 063-A 1 LED3 On Right Side Motor Control Board PC1 2 LED3 On Left Side Motor Control Board PC101 3 LED4 On Dual Board PC70 2 1 3 Display On Optional Meter LED3 Sequence Indicated Error Left Side Motor Control HELP 11 1 Blink Communication Error Left Side Motor Control Board PC101 HELP 12 2 Blinks T rigger Err ...

  • Miller Electric DS-75D12 - page 30

    OM-230 300 Page 26 6-4. 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 4-6). Wire feeder is on, display does not light up, motor does not run, ...

  • Miller Electric DS-75D12 - page 31

    OM-230 300 Page 27 Notes ...

  • Miller Electric DS-75D12 - page 32

    OM-230 300 Page 28 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram ...

  • Miller Electric DS-75D12 - page 33

    OM-230 300 Page 29 204 716-B ...

  • Miller Electric DS-75D12 - page 34

    OM-230 300 Page 30 SECTION 8 − P ARTS LIST 804 785-A 1 2 3 4 5 6 10 12 13 14 16 17 18 19 20 21 26 22 2 Fig 8-4,5 Fig 8-2 Fig 8-3 Fig 8- 6 7 8 9 11 23 24 25 28 Fig 8-4.5 . Hardware is common and not available unless listed. 15 15 14 2 29 29 27 Figure 8-1. Main Assembly ...

  • Miller Electric DS-75D12 - page 35

    OM-230 300 Page 31 Quantity Description Part No. Dia. Mkgs. Item No. Model 12 16 Figure 8-1. Main Assembly 1 See Note Control Box, (Fig 8-2) 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 201 319 Cable, Interconnecting (consisting of) 2 0 . . . . . . . . . . . . . . . . . ...

  • Miller Electric DS-75D12 - page 36

    OM-230 300 Page 32 803 190 . Hardware is common and not available unless listed. 3 4 5 6 5 12 13 15 4 2 14 18 17 16 19 20 21 21 20 22 23 24 1 8 9 10 11 7 Figure 8-2. Control Box Quantity Description Part No. Dia. Mkgs. Item No. Model DS-75S DS-75 D Figure 8-2. Control Box (Figure 8 − 1 Item 1) 1 204 722 Wrapper , Feeder 1 1 . . . . . . . . . . . ...

  • Miller Electric DS-75D12 - page 37

    OM-230 300 Page 33 Quantity Description Part No. Dia. Mkgs. Item No. Model D-75S D-75D Figure 8-2. Control Box (Continued) 17 R1,101 073 562 Pot,Cp Std Slot 1t 2. W 10k Linear 2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 R1,101,70,170 224 597 Pot, Cermet Std Flat 3.75T 2 W 10K Linear 0 4 . . . . . . . . . ...

  • Miller Electric DS-75D12 - page 38

    OM-230 300 Page 34 804 786-A 1 23 5 6 7 8 9 10 12 13 14 15 16 17 18 20 21 22 23 29 30 15 14 24 25 26 19 27 28 4 . Hardware is common and not available unless listed. 11 Figure 8-3. Boom Assembly ...

  • Miller Electric DS-75D12 - page 39

    OM-230 300 Page 35 Quantity Description Part No. Item No. Model 12 16 Figure 8-3. Boom Assembly (Fig 8-1 Item 13) 1 010 313 Pin, Cotter Hair .072 X 1.437 4 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 010 910 W asher , Flat Stl Sae .375 6 6 . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric DS-75D12 - page 40

    OM-230 300 Page 36 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. Description Quantity Model Left Right Figure 8-4. Drive Assembly , Wire (Fig ...

  • Miller Electric DS-75D12 - page 41

    OM-230 300 Page 37 . 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 (Left Side Shown) Item No. Diagram marking Part No. Description Quantity Figure 8-5. Drive Assembly With Motor (Figure 8-1 Items 26 and 28) 1 223 252 T achometer , Optical Encoder 1 . . . . . . . . . . . . . . . . . ...

  • Miller Electric DS-75D12 - page 42

    OM-230 300 Page 38 8 7 6 9 1 2 3 4 5 6 7 13 12 11 10 ST-081 760-C . 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 (Fig 8-1 Item 10) 1 058 427 RING, retaining spool 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric DS-75D12 - page 43

    OM-230 300 Page 39 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 .023 − .0 ...

  • Miller Electric DS-75D12 - page 44

    Notes ...

  • Miller Electric DS-75D12 - page 45

    Notes ...

  • Miller Electric DS-75D12 - page 46

    Notes ...

  • Miller Electric DS-75D12 - page 47

    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. Support Need fast answers to the tough welding questions? Contact your distributor . The expe ...

  • Miller Electric DS-75D12 - page 48

    PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 9 20-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters − ...

Manufacturer Miller Electric Category Welder

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