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Miller Electric and DS-74DX16 manual

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Table of contents for the manual

  • Page 1

    DS-74DX12, and DS-74DX16 OM-1500-14 207 499H 2007 − 07 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-74DX 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

    T ABLE OF CONTENTS SECTION 9 − ELECTRICAL DIAGRAM 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 − P ARTS LIST 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACC[...]

  • Page 5

    OM-1500-14 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007 − 04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols[...]

  • Page 6

    OM-1500-14 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poo[...]

  • Page 7

    OM-1500-14 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-1500-14 Page 4 1-4. California Proposition 65 W arnings W elding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and l[...]

  • Page 9

    OM-1500-14 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007 − 04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bole s ut ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures grav[...]

  • Page 10

    OM-1500-14 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CH[...]

  • Page 11

    OM-1500-14 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants m[...]

  • Page 12

    OM-1500-14 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de toucher d[...]

  • Page 13

    OM-1500-14 Page 9 2-5. P ri nci pal es n or me s de s écu ri té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American [...]

  • Page 14

    OM-1500-14 Page 10[...]

  • Page 15

    OM-1500-14 Page 1 1 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) Optiona[...]

  • Page 16

    OM-1500-14 Page 12 4-2. Installing Control Box And Adjusting Tilt 1 W eld 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 17

    OM-1500-14 Page 13 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 18

    OM-1500-14 Page 14 803 195 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 19

    OM-1500-14 Page 15 803 197-A 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 volts A[...]

  • Page 20

    OM-1500-14 Page 16 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 21

    OM-1500-14 Page 17 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 22

    OM-1500-14 Page 18 4-12. 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), o[...]

  • Page 23

    OM-1500-14 Page 19 4-13. 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 T[...]

  • Page 24

    OM-1500-14 Page 20 SECTION 5 − OPERA TION 5-1. 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[...]

  • Page 25

    OM-1500-14 Page 21 5-4. Jog/Purge Switch 1 803 194 2 1 Jog/Purge Switch 2 Adjust 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 the Jog/Purge switch. If the welding arc does no t i[...]

  • Page 26

    OM-1500-14 Page 22 5-6. Program Push Button 1 3 Program 2 1 Program Display The number of the active program is displayed. 2 Program Push Button Press button to activate program select feature. T o change the pro- gram number , press the Program push button and rotate the Adjust control. 3 Program Push Button LED The LED lights to indicate the Pro-[...]

  • Page 27

    OM-1500-14 Page 23 5-8. Lower Display 2 Wire Speed Amps 1 5 4 3 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 [...]

  • Page 28

    OM-1500-14 Page 24 5-10. 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. Start Crater Pre/Postflow Sequence 5-1 1. Sequence Push Button 1 3 2 W el[...]

  • Page 29

    OM-1500-14 Page 25 5-12. 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 1 Program Display 2 Program Push Button 3 Sequence Push Button 4 Upper Display 5 Upper Display Push Button 6 Lower Display 7 Lower Display Push Button 8 Adjust Control 9 Set[...]

  • Page 30

    OM-1500-14 Page 26 Burnback • If the Setup push button is pressed, the unit allows burnback time to be set. Burnback time and voltage can be specified when the lower display indicates “BURN” an d the upper display indicates the burnback time or voltage. The Adjust control is used to set the desired burnback time or voltage. Burnback settings,[...]

  • Page 31

    OM-1500-14 Page 27 SECTION 6 − SETTING SEQUENCE P ARAMETERS 6-1. Sequence Parameters In A Program . For more information on Sequence Push Button see Section 5-1 1. 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 P[...]

  • Page 32

    OM-1500-14 Page 28 SECTION 7 − SETTING DUAL SCHEDULE P ARAMETERS 7-1. Optional Dual Schedule Switch Diagrams 1 Maint 2P (Maintained-Contact 2-Pole Switch) 2 Maint 1P (Maintained-Contact 1-Pole Switch) . Will not function with trigger hold and dual schedule. A DSS-9 is recommended for this application. 1 2 3 4 B A TR 2 11 22 3 A 4 B DSS-8 DSS-9 1 [...]

  • Page 33

    OM-1500-14 Page 29 7-2. 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 . There is a two-position DIP switch S1 located on motor con- trol boards PC1 and PC101. These switches are factory-set in the off position and must re- main in that position for the unit[...]

  • Page 34

    OM-1500-14 Page 30 7-3. Diagnostics For User Defined Options 2 803 198 1 1 Front Panel 2 Front Panel Board PC20 User Defined Shutdown Error Messages (Additional hardware required for these to be functional) If OPT1 and/or OPT2 are enabled without additional hardware setup, the following error messages will be displayed on the front panel meters. OP[...]

  • Page 35

    OM-1500-14 Page 31 8-2. T roubleshooting ! Disconnect power before troubleshooting. T rouble Remedy Wire feeds, shielding gas flows, but elec- trode 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, meter(s) do not light up, motor [...]

  • Page 36

    OM-1500-14 Page 32 SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram[...]

  • Page 37

    OM-1500-14 Page 33 204 144-C[...]

  • Page 38

    OM-1500-14 Page 34 SECTION 10 − 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 10-4 Fig 10-2 Fig 10-3 Fig 10-5 7 27 8 9 11 23 24 25 29 30 Fig 10-4 . Hardware is common and not available unless listed. 15 15 14 2 31 31 Figure 10-1. Main Assembly[...]

  • Page 39

    OM-1500-14 Page 35 Quantity Description Part No. Dia. Mkgs. Item No. Model DS-12 DS-16 Figure 10-1. Main Assembly 1 See Note Control Box, (Fig 10-2) 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 201 319 Cable, Interconnecting (consisting of) 2 0 . . . . . . . . . . . . . . [...]

  • Page 40

    OM-1500-14 Page 36 10 9 7 8 9 17 18 19 8 6 5 23 21 25 24 22 1 4 3 2 20 803 200 . Hardware is common and not available unless listed. 16 12 13 14 15 11 Figure 10-2. Control Box Description Part No. Dia. Mkgs. Item No. Figure 10-2. Control Box (Figure 10-1 Item 1) Quantity 1 204 722 Wrapper , Feeder 1 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 41

    OM-1500-14 Page 37 Description Part No. Dia. Mkgs. Item No. Figure 10-2. Control Box (Continued) Quantity 18 134 201 Stand-Off Support, PC Card .312/.375w/Post&lock .43 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 204 721 Enclosure, Control 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 42

    OM-1500-14 Page 38 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 10-3. Boom Assembly[...]

  • Page 43

    OM-1500-14 Page 39 Quantity Description Part No. Item No. Model DS-12 DS-16 Figure 10-3. Boom Assembly (Figure 10-1 Item 13) 1 010 313 Pin, Cotter Hair .072 X 1.437 4 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 010 910 Washer , Flat Stl Sae .375 6 6 . . . . . . . . . . . . . . . . . [...]

  • Page 44

    OM-1500-14 Page 40 See T able 10-1 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 10-4. Drive Assembly , Wire Quantity Description Part No. Item No. Model DS-12 DS-16 Figur[...]

  • Page 45

    OM-1500-14 Page 41 Quantity Description Part No. Item No. Model DS-12 DS-16 Figure 10-4. Drive Assembly , Wire (continued) Dia. Mkgs. 184 136 Kit, Brush Holder 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 155 098 Kit, Cover Motor Gearbox (consisting of[...]

  • Page 46

    OM-1500-14 Page 42 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 10-5. Support, Hub & Reel Description Part No. Item No. Quantity Figure 10-5. Support, Hub and Reel (Figure 10-1 Item 10) 1 058 427 Ring, Retaining Spool 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 47

    OM-1500-14 Page 43 T able 10-1. 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 15[...]

  • Page 48

    [...]

  • Page 49

    Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.weldin g .or g Star t Y our Pr ofessional W eldin g Career Now![...]

  • Page 50

    [...]

  • Page 51

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 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 52

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 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[...]