English dropdown-ico

Miller Electric S-74DX manual

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

Go to page of

Similar user manuals

A good user manual

The rules should oblige the seller to give the purchaser an operating instrucion of Miller Electric S-74DX, along with an item. The lack of an instruction or false information given to customer shall constitute grounds to apply for a complaint because of nonconformity of goods with the contract. In accordance with the law, a customer can receive an instruction in non-paper form; lately graphic and electronic forms of the manuals, as well as instructional videos have been majorly used. A necessary precondition for this is the unmistakable, legible character of an instruction.

What is an instruction?

The term originates from the Latin word „instructio”, which means organizing. Therefore, in an instruction of Miller Electric S-74DX one could find a process description. An instruction's purpose is to teach, to ease the start-up and an item's use or performance of certain activities. An instruction is a compilation of information about an item/a service, it is a clue.

Unfortunately, only a few customers devote their time to read an instruction of Miller Electric S-74DX. A good user manual introduces us to a number of additional functionalities of the purchased item, and also helps us to avoid the formation of most of the defects.

What should a perfect user manual contain?

First and foremost, an user manual of Miller Electric S-74DX should contain:
- informations concerning technical data of Miller Electric S-74DX
- name of the manufacturer and a year of construction of the Miller Electric S-74DX item
- rules of operation, control and maintenance of the Miller Electric S-74DX item
- safety signs and mark certificates which confirm compatibility with appropriate standards

Why don't we read the manuals?

Usually it results from the lack of time and certainty about functionalities of purchased items. Unfortunately, networking and start-up of Miller Electric S-74DX alone are not enough. An instruction contains a number of clues concerning respective functionalities, safety rules, maintenance methods (what means should be used), eventual defects of Miller Electric S-74DX, and methods of problem resolution. Eventually, when one still can't find the answer to his problems, he will be directed to the Miller Electric service. Lately animated manuals and instructional videos are quite popular among customers. These kinds of user manuals are effective; they assure that a customer will familiarize himself with the whole material, and won't skip complicated, technical information of Miller Electric S-74DX.

Why one should read the manuals?

It is mostly in the manuals where we will find the details concerning construction and possibility of the Miller Electric S-74DX item, and its use of respective accessory, as well as information concerning all the functions and facilities.

After a successful purchase of an item one should find a moment and get to know with every part of an instruction. Currently the manuals are carefully prearranged and translated, so they could be fully understood by its users. The manuals will serve as an informational aid.

Table of contents for the manual

  • Page 1

    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)[...]

  • 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

    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[...]

  • Page 5

    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[...]

  • Page 6

    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 [...]

  • Page 7

    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. [...]

  • Page 8

    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[...]

  • Page 9

    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[...]

  • Page 10

    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[...]

  • Page 11

    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 [...]

  • Page 12

    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[...]

  • Page 13

    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[...]

  • Page 14

    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[...]

  • Page 15

    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[...]

  • Page 16

    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[...]

  • Page 17

    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[...]

  • Page 18

    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 [...]

  • Page 19

    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 [...]

  • Page 20

    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[...]

  • Page 21

    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 [...]

  • Page 22

    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 [...]

  • Page 23

    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[...]

  • Page 24

    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[...]

  • Page 25

    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 [...]

  • Page 26

    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[...]

  • Page 27

    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[...]

  • Page 28

    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 [...]

  • Page 29

    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[...]

  • Page 30

    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[...]

  • Page 31

    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[...]

  • Page 32

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

  • Page 33

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

  • Page 34

    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[...]

  • Page 35

    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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 36

    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 . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 37

    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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 38

    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[...]

  • Page 39

    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 . . [...]

  • Page 40

    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[...]

  • Page 41

    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 .[...]

  • Page 42

    [...]

  • 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[...]