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OM-1500-6 206 805F
May 2005
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
D-74S, D-74D
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Insta
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Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Note Manufacturer’s Name: Miller Electric Mfg. Co. Manufacturer’s Address: 1635 W. Spencer Street Appleton, WI 54914 USA Declares that the products: D-74S, D-74D conform to the following Directives and Standards: Directives Low Voltage Directive: 73/23/EEC Electromagnetic Compatibility (EMC) Directive: 89/336/EEC Machinery Directives: 89/392/EEC,
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessa
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching HOT PART
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Have only qualified persons remove doors, Do not overload building wiring − be sure power supply system is panels, covers, or guards for main
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800 −463 −6727 or in Toronto 416 −747 −4044, website: www.csa −in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American Na
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. Ce groupe de symboles signifie Avertissement ! Attention ! Risques Indique un message de sécurité particulier d’É
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LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures Le rayonnement de l’arc du procédé de soudage ou même la mort. génère des rayons visibles et invisibles intenses Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation. quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien aérer l
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou S’abstenir de toucher des organes mobiles tels à proximité de surfaces inflammables. que des ventilateurs. Ne pas installer l’appareil à proximité de Maintenir fermés et verrouillés les portes, produits inflammables. panneaux, recouvrements et dispositifs de pro
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2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet : ternet : www.global.ihs.com). www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87
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SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions A. Warning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. AB C C. Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects clear. 1 Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric shock by insulating yourself 1 1.1 1.2 1.3 from work
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3-2. Rating Label For CE Products For label location see Section 5-3. S/N: U 24 V 1 50/60 Hz 1 50/60 = IP 21 I = 10.0A 1 U 100 V I = 750 A X 100 % 2 2 = ST-178 794-A 3-3. Symbols And Definitions Some symbols are found only on CE products. Note Amperes Volts Alternating Current Duty Cycle A V X Degree Of Hertz Program Wire Feed Protection IP Hz Jog Output Trigger Line Connection Set Up Sequence Trigger Hold On Trigger Hold Off Purge Press To Set Start Crater Time Preflow Time Postflow Time Read
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SECTION 4 − INTRODUCTION 4-1. Specifications Welding Type of Input Welding Power Wire Feed Speed Wire Diameter IP Overall Circuit Weight Power Source Type Range Range Rating Dimensions Rating 24 Volts AC Constant Voltage (CV) Standard: 50 To 780 .023 To 1/8 in 100 Volts, IP 21 Length: 35 in 87 lb Single-Phase DC With 14-Pin And ipm (1.3 To 19.8 mpm) (0.6 To 3.2 mm) 750 (889 mm) (39.5 kg) 10 Amperes Contactor Control Amperes, Width: 12-1/2 in 50/60 Hertz Optional High Speed: Max Spool 100% Duty (
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5-2. Equipment Connection Diagrams 1 Welding Power Source 2 Contactor Control/Power Cord 3 Positive (+) Weld Cable 4 Negative ( −) Weld Cable 5 Workpiece 6 Welding Gun 7 Wire Feeder 8 Gas Hose 9 Gas Cylinder and Regulator (Customer Supplied) Shielding gas pressure not to exceed 90 PSI (620 kPa). 1 9 2 3 4 5 8 7 6 803 068 OM-1500-6 Page 12
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5-3. Rear Panel Connections And Rotating Drive Assembly 1 14-Pin Control Cable - 10 Ft (3.0 m) 2 Shielding Gas Valve Fittings Requires fitting with 5/8-18 right- hand threads. Connect customer- supplied gas hose. 3 Weld Cable Terminal 4 Jumper Weld Cable 5 Weld Cable 6 Drive Assembly 7 Drive Assembly Rotation Knob 8 Rating Label Location To rotate the drive assembly, loos- 8 en drive assembly rotation knob, 2 rotate drive assembly, and tighten knob. 1 3 5 4 4 5 6 7 Tools Needed: 9/16, 5/8 in 3/1
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5-4. 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. J J A A K K I B G Circuit common for 24 volts ac circuit. L L H N C C +10 volts dc input from power source to wire feeder with respect to socket D. M M G G D D D Remote control circuit common. F F E E E 0 to +10 volts dc output signal from wire feeder to power source with respect to socket D. H Voltage feedback; 0 to +10 volts dc, 1 vol
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5-7. Installing And Threading Welding Wire Install wire spool. Adjust tension nut so Install wire guides and anti-wear guide. wire is taut when wire feed stops. Install drive rolls. Pressure Indicator Pressure Scale Adjust Rear Pressure Rolls Adjust Front Rolls No Wire Slip Wire Slips NONCONDUCTIVE NONCONDUCTIVE SURFACE SURFACE Tools Needed: Drive Rolls 3/16, 5/64 in Back Of Gun 15/16, 3/8 in End Of Liner For best wire feeding performance, be For soft wire or small diameter stainless To ad
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5-8. Setting Internal DIP Switches Remove wrapper. Left Side Motor Control Board 1 DIP Switch S1 On Motor PC101 Board PC1 Setting Current Detect Override (S1-1) Current detect override is used to disable run-in when a welding pow- Right Side Motor er source is used that doesn’t pro- Control Board PC1 vide current feedback through the 14-pin receptacle. Pins F & H are not present in 14 pin receptacle on machines that don’t provide current feed- back. Install wrapper when finished. P1 This il
