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Miller Electric and SS-74D16 manual

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Table of contents for the manual

  • Page 1

    SS-74S12, SS-74S16, SS-74D12, and SS-74D16 OM-1500-11 207 750K 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) SS-74S/D Swingarc ™ V isit our website at www.MillerWelds.com File: MIG (GMA W)[...]

  • 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-1500-1 1 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 [...]

  • Page 6

    OM-1500-1 1 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 watchin[...]

  • Page 7

    OM-1500-1 1 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-1500-1 1 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-1500-1 1 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 ibl[...]

  • Page 10

    OM-1500-1 1 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 p[...]

  • Page 11

    OM-1500-1 1 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 surcharge[...]

  • Page 12

    OM-1500-1 1 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 e[...]

  • Page 13

    OM-1500 − 1 1 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) Opti[...]

  • Page 14

    OM-1500 − 1 1 Page 10 4-2. Adjusting Control T ilt Bracket 803 155 1 T ilt Bracket 2 Rear Pivot Screw 3 Front Screw Loosen rear pivot screw. Remove front screw . Pivot control down- ward to desired viewing angle. Re- place and tighten front screw . T ight - en pivot screw . 1 2 3 4-3. Installing Boom And Reel Support ST-142 596-C 1 Swivel Plates [...]

  • Page 15

    OM-1500 − 1 1 Page 1 1 4-4. Installing Wire Guide Extension ST-152 323 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 . 1 2 3 4 3/8 in T ools Needed: 803 018 1 W elding Power Source 2 Remote 14 Connection 3 Positive (+) Weld Output Ca[...]

  • Page 16

    OM-1500 − 1 1 Page 12 Ref. 803 019 1 Interconnecting Cable Receptacle 2 Interconnecting Cable 3 14-Pin Control Cable 4-6. Control Box Connections 1 2 3 4-7. 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 contactor control circuit. A J K G Circuit common for 24 volt[...]

  • Page 17

    OM-1500 − 1 1 Page 13 4-8. Removing Safety Collar And Adjusting Boom 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 remove safety collar . Boom should balance in any position from horizontal to 60 degrees above horizontal. If n[...]

  • Page 18

    OM-1500 − 1 1 Page 14 4-1 1. Installing And Threading W elding Wire 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 152 648-A / 803 020 / 802 966 / Ref. 137 391-A / [...]

  • Page 19

    OM-1500 − 1 1 Page 15 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 feedba[...]

  • Page 20

    OM-1500 − 1 1 Page 16 T ools Needed: 1/4 in 4-13. Optional E quipment DIP Switch Settings (For Models with Meters Only) 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 Ref. 803 154 Remove wrapper . Install wrapper [...]

  • Page 21

    OM-1500 − 1 1 Page 17 5-2. Power Switch 1 Power Switch 1 803 153 5-3. Jog/Purge 1 803 152 2 1 Jog/Purge Push Button 2 Wire Speed Control Pressing the J og/Purge switch allows the op- erator to jog wire without energizing the weld power or gas valve circuit. • The unit provides the ability to jog the wire feeder by means of the gun trigger or th[...]

  • Page 22

    OM-1500 − 1 1 Page 18 5-4. T rigger Hold Switch 1 T rigger Hold Switch Trigger hold allows the operator to weld with- out holding the gun trigger . • T o use the trigger hold function, place the trigger hold switch in the On position. • T he operator must hold the trigger for a mini- mum of 2 seconds, but not longer than 6 seconds before rele[...]

  • Page 23

    OM-1500 − 1 1 Page 19 SECTION 6 − MAINTENANCE 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 vacuum inside. Duri[...]

  • Page 24

    OM-1500 − 1 1 Page 20 6-2. Diagnostics • Error Indications Error conditions are indicated by LED3 on PC 1 or on display (on models with meters). T o view LED3, turn Off unit, remove wrapper , an d turn unit On. LED3 is most easily observed from the left side of the unit. The LED blinks in a 2.5 second cycle. The number of blinks in this period [...]

  • Page 25

    OM-1500 − 1 1 Page 21 6-3. T roubleshooting Y Disconnect power before troubleshooting T rouble Remedy Wire feeds, shielding gas flows, but electrode wire is not energized. Check interconnecting cord connections. If secure, check cord for continuity and repair or replace (see Sections 4-5 and 4-6 ). Wire feeder is on, display does not light up, mo[...]

  • Page 26

    OM-1500-1 1 Page 22 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram 202 246-C[...]

  • Page 27

    OM-1500 − 1 1 Page 23 SECTION 8 − P ARTS LIST 802 866-C 1 2 3 4 5 6 7 8 7 10 11 12 13 21 9 Fig 8-2 Fig 8-3 Fig 8-5 2 14 15 18 22 23 24 25 26 27 Fig 8-4 28 29 30 18 31 32 . Hardware is common and not available unless listed. 16 17 20 19 33 Figure 8-1. Main Assembly[...]

  • Page 28

    OM-1500 − 1 1 Page 24 Quantity Description Part No. Dia. Mkgs. Item No. Model 12 16 Figure 8-1. Main Assembly 1 See Note Control Box, (Figure 8-2) 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 201 319 Cable, Interconnecting (consisting of) 1 . . . . . . . . . . . . . . . . . . [...]

  • Page 29

    OM-1500 − 1 1 Page 25 803 028-B . Hardware is common and not available unless listed. 2 12 14 15 16 19 20 23 26 17 22 1 3 4 5 6 7 8 9 10 11 9 8 13 24 25 21 18 27 Figure 8-2. Control Box Quantity Description Part No. Dia. Mkgs. Item No. Model 74S 74D Figure 8-2. Control Box (Figure 8-1 Item 1) 1 RC40 047 637 Housing Rcpt+Skts, (service kit) 1 1 . [...]

  • Page 30

    OM-1500 − 1 1 Page 26 Quantity Description Part No. Dia. Mkgs. Item No. Model 74S 74D Figure 8-2. Control Box (Figure 8-1 Item 1) (Continued) 10 070 371 Blank, Snap-In Nyl 1.125 Mtg Hole 2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 200 553 Bracket, Control Box Mounting 1 1 . . . . . . .[...]

  • Page 31

    OM-1500 − 1 1 Page 27 ST-142 601-F 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 8 9 24 27 28 20 21 19 22 23 26 25 26 . Hardware is common and not available unless listed. Figure 8-3. Boom Assembly[...]

  • Page 32

    OM-1500 − 1 1 Page 28 Quantity Description Part No. Item No. Model 12 16 Figure 8-3. Boom Assembly (Figure 8-1 Item 13) 1 000 527 Plug, 0.875 Inch 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 159 991 Boom, Single 1 0 . . . . . . . . . . . . . . . . . . . . [...]

  • Page 33

    OM-1500 − 1 1 Page 29 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[...]

  • Page 34

    OM-1500 − 1 1 Page 30 Description Part No. Item No. Quantity Dia. Mkgs. Figure 8-4. Drive Assembly , Wire (Figure 8-1 Item 27) 1 010 668 Screw , Cap Stl Sch .250-20 X 1.500 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 172 075 Carrier , Drive Roll W/Components 24 Pitch 4 . . . . . . . . . . [...]

  • Page 35

    OM-1500 − 1 1 Page 31 ST-146 339-B 1 2 3 4 5 6 7* 9 10 11 12 13 14 2 3 8 *Includes Item 8 . 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 (Figure 8-1 Item 10) 1 142 399 Support, Reel 1 . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 36

    OM-1500 − 1 1 Page 32 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 95[...]

  • Page 37

    OM-1500 − 1 1 Page 33 Notes[...]

  • Page 38

    [...]

  • Page 39

    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 40

    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[...]