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OM-1500-13 207 494H
2006 −05
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas-and Self-Shielding)
Submerged (SAW) Welding
Description
Wire Feeder
(Use with CV Power Sources)
™
DS-74S/D Swingarc
DS-74S12, DS-74S16, DS-74D12, and DS-74D16
File: MIG (GMAW)
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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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 − INTRODUCTION 3-1. Specifications Type of Input Welding Power Wire Feed Speed Wire Diameter Welding Circuit Weight Power Source Type Range Range Rating Standard: 50 To 780 ipm .023 To 1/8 in (0.6 12 ft (3.7 m): 100 Volts, (1.3 To 19.8 mpm) 24 Volts AC Constant Voltage (CV) To 3.2 mm) 207 lb (94 kg) 750 Amperes, 100% Single-Phase DC With 14-Pin And Duty Cycle 10 Amperes Optional High Speed: 92 Contactor Control Max Spool Weight: 16 ft (4.9 m): 50/60 Hertz To 1435 ipm (2.3 To 36.5 60 lb
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4-2. Installing Control Box And Adjusting Tilt 1 Weld Control 2 Bracket 3 Screw Bracket and screws are installed onto bottom of control at factory. 4 Swivel 1 Loosen screws. Place control on swivel and slide forward. Tighten screws. 5 2 5 Tilt Bracket 6 Rear Pivot Screw 6 7 Front Screw Loosen rear pivot screw. Remove front screw. Pivot control down- 4 ward to desired viewing angle. Re- place and tighten front screw. Tight- 7 en pivot screw. 3 Tools Needed: 3/8 in 803 182 4-3. Installing Boom And
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4-4. Installing Wire Guide Extension 1 Wire Guide Fitting 2 Bolt 3 Monocoil Liner 1 4 Wire Guide Extension Tighten bolt to secure liner in wire 4 guide fitting. Do not overtighten bolt and crush liner. 3 Repeat procedure for opposite 2 side. Tools Needed: 3/8 in ST-152 383 OM-1500-13 Page 11
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4-5. Equipment Connection Diagram 1 Welding Power Source 2 Remote 14 Connection 3 Negative ( −) Weld Output Cable 4 Positive (+) Weld Output Cable 5 Workpiece 6 Weld Control 12 7 Boom 1 8 Gun 9 Swivel 10 Pipe Post And Base 2 11 Gas Hose 12 Gas Supply and Regulator (Customer Supplied) Shielding gas pressure not to exceed 100 PSI (689 kPa). 3 4 5 11 6 7 10 9 8 803 185 OM-1500-13 Page 12
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4-6. Control Box Connections 1 Interconnecting Cables 2 Interconnecting Cable Receptacles 3 14-Pin Cord 1 2 3 Ref. 803 187 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. 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 vol
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4-8. Removing Safety Collar And Adjusting Boom 1 Locking Knob Tighten 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 4 balance in any position from hori- zontal to 60 degrees above hori- zontal. If necessary, adjust boom as follows: 2 Threaded Rod 3 Jam Nut Loosen jam nut and turn threaded rod until boom balances. Tighten 5 jam nut. Be sure several full threads are
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4-11. Installing And Threading Welding Wire Tools Needed: 3/8, 15/16 in 3/16, 5/64 in Install wire spool. Ad- just tension nut so wire is taut when wire feed stops. Pressure Adjust Pressure Indicator Scale Install wire guide. Pressure Adjust Drive Rolls Install drive rolls. Gun Cable End Of Liner NONCONDUCTIVE NONCONDUCTIVE SURFACE SURFACE No Wire Slip Wire Slips Be sure that outlet cable has proper For soft wire or small diameter stainless To adjust drive roll pressure, hold nozzle size l
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4-12. 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 i
