Miller Electric D-64 Owner's Manual
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Miller Electric D-64 Owner's Manual

Miller Electric D-64 Owner's Manual

Wire feeder (use with cv power sources)
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www.MillerWelds.com
D-64
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)

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  • Page 1 Visit our website at www.MillerWelds.com OM-1582 September 2001 Processes MIG (GMAW) Flux Cored (FCAW) (Gas- and Self-Shielded) Submerged (SAW) Description Wire Feeder (Use with CV Power Sources) D-64 138 593X...
  • Page 2 ISO 9001 Quality System Standard. service information for your particular model are also provided. 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 catalog sheets.

  • Page 3: Table Of Contents

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage 1-2. Arc Welding Hazards 1-3. Additional Symbols for Installation, Operation, and Maintenance WARNING 1-4. Principal Safety Standards 1-5. EMF Information This product, when used SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION for welding or cutting, 1-1.
  • Page 4 Declaration of Conformity for European Community (CE) Products Note This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA D-64...

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2.
  • Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    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.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields 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 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’...

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT 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. Y Identifie un message de sécurité particulier. Signifie NOTA ;...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. D Ne pas placer l’appareil sur, au-dessus ou à proxi- mité de surfaces infllammables. D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique –...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions S-178 936 A. Warning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. Welding wire and drive parts are at welding voltage during operation –...

  • Page 14: Rating Label For Ce Products

    2-2. Rating Label For CE Products For label location see Section 4-4. 2-3. Symbols And Definitions Note Some symbols are found only on CE products. Amperes Degree Of Protection Press To Set Purge Burnback Time Increase OM-1582 Page 10 S/N: 50/60 50/60 IP 21...

  • Page 15: Section 3 - Introduction

    SECTION 3 – INTRODUCTION 3-1. Specifications Type of Input Welding Power Power Source Type 24 Volts AC Constant Voltage (CV) Single-Phase DC With 14-Pin And 10 Amperes Contactor Control 50/60 Hertz SECTION 4 – INSTALLATION 4-1. Site Selection Welding Wire Feed Wire Diameter Circuit Speed Range...

  • Page 16: Gun Recommendation Table

    4-2. Gun Recommendation Table Process GMAW – Hard or Cored Wires Roughneck C-Series Guns: 300, 400, 500, FCAW – Self-Shielding Wires 4-3. Equipment Connection Diagrams OM-1582 Page 12 And 600 Amp. FC-1260 Or FC-1150 Welding Power Source Contactor Control/Power Cord Positive (+) Weld Cable Negative (–) Weld Cable Workpiece...

  • Page 17: Rear Panel Connections

    4-4. Rear Panel Connections Tools Needed: 9/16, 5/8 in 3/16 in 4-5. 14-Pin Plug Information Pin* *The remaining pins are not used. Pin Information 24 volts ac with respect to socket G. Contact closure to A completes 24 volts ac contactor control circuit. Circuit common for 24 volts AC circuit.

  • Page 18: Wire Type, Size, And Feed Speed Capability Table

    4-6. Wire Type, Size, And Feed Speed Capability Table Motor Speed Wire Type Standard Standard Standard Optional High Speed 4-7. Motor Start Control Tools Needed: Non-Conductive 1/4 in OM-1582 Page 14 Wire Size .023 To 5/64 in (0.6 To 2 mm) 3/32 To 7/64 in (2.4 To 2.8 mm) 1/8 in (3.2 mm) .023 To 5/64 in (0.6 To 2 mm)

  • Page 19: Rotating The Drive Assembly

    4-8. Rotating The Drive Assembly Tools Needed: 1/4 in 3/16 in Remove screws (6) from front edge of wrapper, and loosen screws on back edge of wrapper. Front Panel Drive Assembly Rotation Adjustment Opening Drive Assembly Ref. 143 259-G / Ref. ST-153 093-A OM-1582 Page 15...

  • Page 20: Installing And Threading Welding Wire

    4-9. Installing And Threading Welding Wire Be sure that outlet cable has proper size liner for the welding wire size. When installing gun, position liner extending from outlet wire guide as close as pos- sible to drive rolls without touching. Install gun.

  • Page 21: Optional Equipment Dip Switch Settings

    4-10. Optional Equipment DIP Switch Settings Spot Time Range Selection X Means switch can be in either position. . Means switch must be in this position. Tools Needed: 1/4 in If wire feeder is equipped with a voltage sensing lead, set DIP switch S3 to the OFF position (up).

  • Page 22: Section 5 - Operation

    SECTION 5 – OPERATION 5-1. Front Panel Controls Voltmeter (Optional) (See Section 4-10) Wire Speed Meter (Optional) Factory set to display inches per minute. If display of meters per minute is desired, see Section 4-10. Schedule A Wire Speed Control The scale is calibrated in inches per minute x 100 and meter per minute.

  • Page 23: Overload Protection And Optional Side Panel Controls

    5-2. Overload Protection And Optional Side Panel Controls Circuit Breaker CB1 CB1 protects wire feed motor from overload. Press to reset. Preflow Control Control sets time gas flows before welding wire is energized. Spot Time Control Factory set for 0 to 5 seconds of spot time. If 0 to 2.5 seconds is desired, see Section 4-10.

  • Page 24: Troubleshooting

    6-2. Troubleshooting Trouble Wire feeds, shielding gas flows, but elec- Check interconnecting cord connections. If secure, check cord for continuity and repair or replace (see trode wire is not energized. Sections 4-3 and 4-4). Wire feeder is on, meter(s) do not light Check and reset CB1 (see Section 5-2).
  • Page 25 Notes OM-1582 Page 21...

  • Page 26: Section 7 - Electrical Diagram

    SECTION 7 – ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram OM-1582 Page 22...
  • Page 27 197 518–A OM-1582 Page 23...

  • Page 28: Section 8 - Parts List

    SECTION 8 – PARTS LIST Hardware is common and not available unless listed. Fig 8-2 OM-1582 Page 24 Fig 8-5 Fig 8-5 Figure 8-1. Main Assembly 143 225-K...
  • Page 29 Item Part ....143 160 ....058 427 ....180 573 .
  • Page 30 Hardware is common and not available unless listed. 143 226-G Figure 8-2. Control Box OM-1582 Page 26...
  • Page 31 Item Dia. Part Mkgs....139 235 ..... Fig 8-4 .
  • Page 32 Item Dia. Part Mkgs..... . . 119 951 ..... . 107 983 .
  • Page 33 Item Dia. Part Mkgs..R1,2 ..073 562 ....149 654 .
  • Page 34 Hardware is common and not available unless listed. Item Dia. Part Mkgs..S31,32 ..011 770 ..PC70 ..150 591 ..PLG16,54,76 115 093 .
  • Page 35 Item Dia. Part Mkgs..PC80 ..196 746 ....093 551 ..PLG16,54,76,76 .
  • Page 36 Item Dia. Part Mkgs....010 668 ....172 075 .
  • Page 37 Guide Intermediate Guide Inlet OM-1582 Page 33...
  • Page 38 Notes OM-1582 Page 34...
  • Page 39 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 40: Owner's Record

    Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...

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