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Miller Electric and DS-74D16 manual

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Table of contents for the manual

  • Page 1

    DS-74S12, DS-74S16, DS-74D12, and DS-74D16 OM-1500-13 207 494H 2006 − 05 Processes Description MIG (GMAW) W elding Flux Cored (FCA W ) W elding (Gas-and Self-Shielding) Submerged (SAW) W elding Wire Feeder (Use with CV Power Sources) DS-74S/D Swingarc ™ File: MIG (GMA W) V isit our website at www.MillerWelds.com[...]

  • 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[...]

  • 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 . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-1500-13 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 i n the adjoining symbols. Y Marks a special safety m[...]

  • Page 6

    OM-1500-13 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[...]

  • Page 7

    OM-1500-13 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.[...]

  • Page 8

    OM-1500-13 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 [...]

  • Page 9

    OM-1500-13 Page 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 util isés Sy mbole graphique d’avert iss ement ! Att ention ! Cette pro - cédur e comporte d es risques poss ible[...]

  • Page 10

    OM-1500-13 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[...]

  • Page 11

    OM-1500-13 Page 7 2-3 . Dange rs suppléme ntaire s en r e lation avec l’installa tion, le f onc tionneme nt e t l a maintenance 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[...]

  • Page 12

    OM-1500-13 Page 8 2-5. Princi pales nor mes de sécur ité 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[...]

  • Page 13

    OM-1500-13 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 And Contactor Control Standard: 50 T o 780 ipm (1.3 T o 19.8 mpm) Optional [...]

  • Page 14

    OM-1500-13 Page 10 4-2. Installing Control Box And Adjusting T ilt 1 Weld 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 . Piv[...]

  • Page 15

    OM-1500-13 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[...]

  • Page 16

    OM-1500-13 Page 12 803 185 1 W elding Power Source 2 Remote 14 Connection 3 Negative ( − ) W eld Output Cable 4 Positive (+) Weld Output Cable 5 W orkpiece 6 Weld Control 7 Boom 8 Gun 9 Swivel 10 Pipe Post And Base 1 1 Gas Hose 12 Gas Supply and Regulator (Customer Supplied) . Shielding gas pressure not to exceed 100 PSI (689 kPa). 4-5. Equipment[...]

  • Page 17

    OM-1500-13 Page 13 Ref. 803 187 1 Interconnecting Cables 2 Interconnecting Cable Receptacles 3 14-Pin Cord 4-6. Control Box Connections 1 3 2 4-7. 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[...]

  • Page 18

    OM-1500-13 Page 14 4-8. 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[...]

  • Page 19

    OM-1500-13 Page 15 4-1 1. Installing And Threading Welding Wire T ools Needed: 3/16, 5/64 in 3/8, 15/16 in Install wire spool. Ad- just tension nut so wire is taut when wire feed stops. Install wire guide. Pressure Indicator Scale Pressure Adjust Install drive rolls. NONCONDUCTIVE SURF ACE NONCONDUCTIVE SURF ACE No Wire Slip Wire Slips Drive Rolls [...]

  • Page 20

    OM-1500-13 Page 16 4-12. Setting Internal DIP Switches Position Settings And Results For DIP Switch S1 On PC1 And PC101 On = Current detect over- ride. For welding power sources that don’t provide current feedback through the 14-pin receptacle. Run- in is inactive. Off = Current must be detected from power sources that provide current feedback th[...]

  • Page 21

    OM-1500-13 Page 17 T ools Needed: 1/4 in 4-13. Optional Equipment DIP Switch Settings 12 3 45 Or Or High Speed Motor Meters/Minute High Speed Motor Inches/Minute Standard Motor Meters/Minute Standard Motor Inches/Minute Digital Meter Functions 12 3 45 12 3 45 12 3 45 803 188 Remove wrapper . 1 Digital Meter Board PC60 2 Meter Board Switch S2 Instal[...]

  • Page 22

    OM-1500-13 Page 18 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[...]

  • Page 23

    OM-1500-13 Page 19 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[...]

  • Page 24

    OM-1500-13 Page 20 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. Check 14-pin cord. Check gas hose and fittings. Check gun cable. Replace cracked parts. 6 Months Blow out or va[...]

  • Page 25

    OM-1500-13 Page 21 6-2. Diagnostics 803 063-A 1 LED3 On Right Side Motor Control Board PC1 2 LED3 On Left Side Motor Control Board PC101 3 LED3 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[...]

  • Page 26

    OM-1500-13 Page 22 6-3. 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 4-5). Wire feeder is on, display does not light up, motor does not run,[...]

  • Page 27

    OM-1500-13 Page 23 Notes[...]

  • Page 28

    OM-1500-13 Page 24 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram[...]

  • Page 29

    OM-1500-13 Page 25 204 716-B[...]

  • Page 30

    OM-1500-13 Page 26 SECTION 8 − P ARTS LIST 803 189-C 1 2 3 4 5 6 10 12 13 14 16 17 18 19 20 21 26 22 28 2 Fig 8-4 Fig 8-2 Fig 8-3 Fig 8-5 7 27 8 9 11 23 24 25 29 30 Fig 8-4 . Hardware is common and not available unless listed. 15 15 14 2 31 31 Figure 8-1. Main Assembly[...]

  • Page 31

    OM-1500-13 Page 27 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 . . . . . . . . . . . . . . . . . [...]

  • Page 32

    OM-1500-13 Page 28 803 190 . 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 D-74S D-74D Figure 8-2. Control Box (Figure 8 − 1 Item 1) 1 204 722 Wrapper , feeder 1 1 . . . . . . . . . . . . .[...]

  • Page 33

    OM-1500-13 Page 29 Quantity Description Part No. Dia. Mkgs. Item No. Model D-74S D-74D 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 . . . . . . . . .[...]

  • Page 34

    OM-1500-13 Page 30 ST-142 306-H 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[...]

  • Page 35

    OM-1500-13 Page 31 Quantity Description Part No. Item No. Model 12 16 Figure 8-3. Boom Assembly (Fig 8-1 Item 14) 1 010 313 Pin, Cotter Hair .072 X 1.437 4 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 010 910 W asher , Flat Stl Sae .375 6 6 . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 36

    OM-1500-13 Page 32 See T able 8-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 802 977-B 1 32 33 34 36 35 30 28 29 31 37 27 40 39 38 6 5 3 2 4 7 9 8 11 10 24 25 20 12 15 18 16 22 14 17 19 21 23 22 14 13 26 Figure 8-4. Drive Assembly , Wire Q uantity Description Part No. Item No. Model DS-74S DS-74 D Fig[...]

  • Page 37

    OM-1500-13 Page 33 Quantity Description Part No. Item No. Model DS-12 DS-16 Figure 8-4. Drive Assembly , Wire (continued) Dia. Mkgs. 184 136 Kit, Brush Holder 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 155 098 Kit, Cover Motor Gearbox (consisting of)[...]

  • Page 38

    OM-1500-13 Page 34 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 8-5. Support, Hub & Reel Description Part No. Item No. Quantity Figure 8-5. Support, Hub & Reel (Fig 8-1 Item 1 1) 1 058 427 RING, retaining spool 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 39

    OM-1500-13 Page 35 T able 8-1. Drive Roll and Wire Guide Kits .023-.025 in. 0.6 mm 151 024 087 130 .030 in. 0.8 mm 151 025 053 695 .035 in. 0.9 mm 151 026 053 700 151 036 072 000 151 052 132 958 .045 in. 1.1/1.2 mm 151 027 053 697 151 037 053 701 151 053 132 957 151 070 083 489 .052 in. 1.3/1.4 mm 151 028 053 698 151 038 053 702 151 054 132 956 151[...]

  • Page 40

    Notes[...]

  • Page 41

    Notes[...]

  • Page 42

    Notes[...]

  • Page 43

    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[...]

  • Page 44

    PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks 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 AX: 920-735-4134 Int ernati onal F A X: 920-735-4125 European Headqua rters − U[...]