Miller Electric S-74DX manual

S-74DX Processes Description MIG (GMAW) W elding Flux Cored (FCA W ) W elding (Gas- And Self-Shielded) Wire Feeder OM-1500-9 207 749K 2006 − 05 Visit our website at www.MillerWelds.com File: MIG (GMA W)[...]

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[...]

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

dec_wire_6/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W . Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r .l. Phon[...]

OM-1500-9 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 me[...]

OM-1500-9 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 [...]

OM-1500-9 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. [...]

OM-1500-9 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 Welding Society Standard A WS[...]

OM-1500-9 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 ibles[...]

OM-1500-9 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 pea[...]

OM-1500-9 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 [...]

OM-1500-9 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 eld[...]

OM-1500-9 Page 9 SECTION 3 − DEFINITIONS 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 56 + 2.3 S-178 936 A. W arning! W atch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. W elding wire and drive parts are at welding voltage during operation − keep hands and metal objects clear . 1 Electric s[...]

OM-1500-9 Page 10 ST-178 794-A 50/60 S/N: 24 10.0 Hz 50/60 IP 21 V 100 A 750 X 100 % V U 1 = A I 1 = 1 U 2 = I 2 = 3-2. Rating Label For CE Products For label location see Section 5-2. 3-3. Symbols And Definitions Some symbols are found only on CE products. Note A Amperes V V olts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz Pr[...]

OM-1500-9 Page 1 1 SECTION 4 − INTRODUCTION 4-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating IP Rating Overall Dimensions 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 ip[...]

OM-1500-9 Page 12 5-2. Rear Panel Connections And Rotating Drive Assembly 802 824-A / 802 825-A 2 3 4 1 14-Pin Control Cable − 10 ft (3.0 m) 2 Shielding Gas V alve Fitting Requires fitting with 5/8-18 right- hand threads. Connect customer- supplied gas hose. . Shielding gas pressure not to exceed 100 PSI (689 kPa). 3 Weld Cable T erminal 4 Weld C[...]

OM-1500-9 Page 13 5-3. 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 volts ac circuit. C L N H D M G C +10 volts dc input from power source to wire feeder with respect to socket D. D M G E F D Remo[...]

OM-1500-9 Page 14 5-6. Installing And Threading Welding Wire Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / 802 954 / S-0627-A T ools Needed: . 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 possible to drive rolls without touching. Install [...]

OM-1500-9 Page 15 5-7. Setting Internal DIP Switches 1 DIP Switch S1 2 DIP Switch S4 (Not For Customer Use) D IP switch S1 allows the user to make a num- ber of choices af fecting unit operation. w Defining Motor Speed (S1-7 & 8) Switches 7 and 8 allow the user to define whether the motor in use is standard speed (50-780 inches per minute), or [...]

OM-1500-9 Page 16 5-8. Power Source Selection Menu . When the feeder is turned on, the Power Source Selection Menu allows the operator to se- lect a default power source. Selecting a default power source, automatically sets the correct Vmin and Vmax set- tings for adjusting the output voltage of the power source. First Time Feeder Is T urned On The[...]

OM-1500-9 Page 17 SECTION 6 − OPERA TION 6-1. Operational T erms The following is a list of terms and their definitions as they apply to this wire feeder: General T erms: Cold Wire Jog Feeding wire without contactor or gas valve being energized. Sequence A portion of the weld program, such as preflow , run-in, start, weld, crater , burnback, and [...]

OM-1500-9 Page 18 6-4. Front Panel Controls Program Start Crater Pre/Postflow T rigger Hold Adjust V olts Time (sec) Wire Speed Amps Sequence Setup Dual Schedule See Section 6-5 See Section 6-6 See Section 6-9 See Section 6-8 See Section 6-7 See Section 6-3 See Section 6-9 See Section 6-8 See Section 6-7 See Section 6-5 See Section 6-6 See Section [...]

OM-1500-9 Page 19 6-5. Upper Display 5 2 V olts Time (sec) 1 4 3 1 Upper Display The upper display shows voltage or time. The unit displays both preset and actual arc voltage. When the unit is in a welding state, actual arc voltage is displayed. The upper display shows welding sequence time when the T ime LED is illuminated. 2 Upper Display Push Bu[...]

OM-1500-9 Page 20 6-6. Lower Display 1 Lower Display The lower display shows wire speed or amperage. The unit displays and adjusts only preset wire speed at idle. When the unit is in a welding state, actual wire speed is displayed for the active welding sequence. 2 Lower Display Push Button Press button to choose between wire speed or amperage func[...]

OM-1500-9 Page 21 6-8. Adjust Control Adjust 1 1 Adjust Control The Adjust control is used to change various sequence parame- ters, and to select various se- quences. Refer to the section for th e function in question for informa- tion related to using the Adjust con- trol. 1 Non-CE Models CE Models Start Crater Pre/Postflow Sequence 6-9. Sequence [...]

OM-1500-9 Page 22 6-10. Auxiliary Menus Program Start Crater Pre/Postflow T rigger Hold Adjust V olts Time (sec) Wire Speed Amps Sequence Setup Dual Schedule 3 4 2 9 8 1 5 7 6 3 2 1 8 9 5 7 6 4 Non-CE Models CE Models 1 Program Display 2 Program Push Button 3 Sequence Push Button 4 Upper Display 5 Upper Display Push Button 6 Lower Display 7 Lower D[...]

OM-1500-9 Page 23 Reset T o Factory Settings A reset menu is displayed if the following four push buttons are pressed simultaneously: Program, Sequence, upper display , and Set- up. The upper display indicates “WIPE” . The lower display indicates “OFF”. The lower push button is active indicating that the Adjust con- trol can be used to chan[...]

OM-1500-9 Page 24 OPT2 • If the Setup push button is pressed, the unit allows OPT2 to be disabled or enabled. The upper display shows “OPT2”. Lower dis- play shows “On” or “Off”. The Adjust Control is used to select either “On” or “Off”. “OPT2” is a second input that may be used with an external device, such as a gas flow [...]

OM-1500-9 Page 25 SECTION 7 − SETTING SEQUENCE P ARAMETERS 7-1. Sequence Parameters In A Program . For more information on Sequence Push Button see Section 6-9. If time is set to zero in W eld sequence, welding continues until gun trigger is released. If time is set to zero in any timed sequence except Weld, the sequence is skipped. T rigger Pres[...]

OM-1500-9 Page 26 SECTION 8 − SETTING DUAL SCHEDULE P ARAMETERS 8-1. Optional Dual Schedule Switch Diagrams 1 Maint 2P (Maintained-Contact 2-Pole Switch) 2 Maint 1P (Maintained-Contact 1-Pole Switch) 1 2 3 4 B A TR 2 11 22 3 A 4 B DSS-8 DSS-9 1 SECTION 9 − MAINTENANCE 9-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Repl[...]

OM-1500-9 Page 27 9-2. Diagnostics LED3-Related Error Indications Error conditions are indicated by LED3 on PC1. T o view LED3, turn Off unit, remove wrapper , and 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 indicates the type of error . Th e pr[...]

OM-1500-9 Page 28 SECTION 10 − ELECTRICAL DIAGRAM Figure 10-1. Circuit Diagram 200 592-H[...]

OM-1500-9 Page 29 Notes[...]

OM-1500-9 Page 30 SECTION 1 1 − P ARTS LIST 802 712-A . Hardware is common and not available unless listed. 21 4 1 2 6 14 15 16 17 18 19 20 5 7 8 9 10 11 12 11 10 13 3 Figure 1 1-1. Main Assembly[...]

OM-1500-9 Page 31 Item No. Part No. Description Quantity Figure 1 1-1. Main Assembly 1 159 647 Insulator , Motor Clamp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 159 646 Clamp, Motor Base 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-1500-9 Page 32 802 802-D . Hardware is common and not available unless listed. 15 11 18 6 17 10 9 8 5 14 11 1 3 12 1 2 3 4 7 10 19 20 21 22 24 23 Figure 1 1-2. Control Box Item No. Diagram marking Part No. Description Quantity Figure 1 1-2. Control Box (Figure 1 1-1 Item 21) 1 200 555 Wrapper , Feeder 1 . . . . . . . . . . . . . . . . . . . . . [...]

OM-1500-9 Page 33 Item No. Diagram marking Part No. Description Quantity Figure 1 1-2. Control Box (Figure 1 1-1 Item 21) (Continued) 20 S2 200 295 Switch, Rocker Spdt 15a 12v (On)-Off-(On) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 207 741 Nameplate 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-1500-9 Page 34 See T able 1 1-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 803 790-A 20 11 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 1 2 3 4 5 6 22 21 19 18 17 16 15 14 19 13 12 11 9 10 8 7 6 5 4 3 2 1 Figure 1 1-3. Drive Assembly , Wire Item No. Diagram marking Part No. Description Quantity Fig[...]

OM-1500-9 Page 35 Item No. Diagram marking Part No. Description Quantity Figure 1 1-3. Drive Assembly , Wire (Figure 1 1-1 Item 4) (continued) 15 182 155 Spring 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 132 746 Bushing, Spring 2 . . [...]

OM-1500-9 Page 36 Each kit contains an inlet guide, intermediate guide, and 045 233 antiwear guide W/604 612 setecrew 8-32 x .125, along with 4 drive rolls. UC-GROOVE VK-GROOVE U-GROOVE V -GROOVE 4 Roll Kit Drive Roll 4 Roll Kit Drive Roll 4 Roll Kit Drive Roll 4 Roll Kit Drive Roll Wire Size Fraction Metric Inlet Guide Intermediate Guide .023-.025[...]

Notes W or k l i k e a P r o! Pros wel d and cut safel y . Read the safety rules at the beginni ng of this manual .[...]

[...]

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[...]

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[...]