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Miller Electric DS-74D16 Swingarc Owner's Manual

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DS-74S/D Swingarc
DS-74S12, DS-74S16, DS-74D12, and DS-74D16
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)
File: MIG (GMAW)

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Summary of Contents for Miller Electric DS-74D16 Swingarc

  • Page 1 DS-74S/D Swingarc Visit our website at www.MillerWelds.com DS-74S12, DS-74S16, DS-74D12, and DS-74D16 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) File: MIG (GMAW)
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment.
  • Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    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: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, 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 Welding and Cut- ting of Containers and Piping, American Welding Society Standard F4.1 from Global...

  • Page 9: Section 2 − Consignes De Sécurité − À Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION Y 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.
  • Page 10 LES RAYONS D’ARC peuvent entraî- ner des brûlures aux yeux et à la peau. 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.

  • Page 11: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil

    2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la 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 l’installation électrique −...

  • Page 12: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, 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 for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).

  • Page 13: Section 3 − Introduction

    SECTION 3 − INTRODUCTION 3-1. Specifications Type of Input Welding Power Power Source Type 24 Volts AC Constant Voltage (CV) Single-Phase DC With 14-Pin And 10 Amperes Contactor Control 50/60 Hertz Maximum Height With 4 ft (1.2 m) Post Vertical Lift Of Boom SECTION 4 −...

  • Page 14: Installing Control Box And Adjusting Tilt

    4-2. Installing Control Box And Adjusting Tilt Tools Needed: 3/8 in 4-3. Installing Boom And Reel Support Tools Needed: 3/8, 3/4 in OM-1500-13 Page 10 Weld Control Bracket Screw Bracket and screws are installed onto bottom of control at factory. Swivel Loosen screws.

  • Page 15: Installing Wire Guide Extension

    4-4. Installing Wire Guide Extension Tools Needed: 3/8 in Wire Guide Fitting Bolt Monocoil Liner Wire Guide Extension Tighten bolt to secure liner in wire guide fitting. Do not overtighten bolt and crush liner. Repeat procedure for opposite side. ST-152 383 OM-1500-13 Page 11...

  • Page 16: Equipment Connection Diagram

    4-5. Equipment Connection Diagram OM-1500-13 Page 12 Welding Power Source Remote 14 Connection Negative (−) Weld Output Cable Positive (+) Weld Output Cable Workpiece Weld Control Boom Swivel 10 Pipe Post And Base 11 Gas Hose 12 Gas Supply and Regulator (Customer Supplied) Shielding gas pressure not to exceed 100 PSI (689 kPa).

  • Page 17: Control Box Connections

    4-6. Control Box Connections 4-7. 14-Pin Plug Information Pin* *The remaining pins are not used. Pin Information 24 volts ac with respect to socket G. Contact closure to A completes 24 volts ac contactor control circuit. Circuit common for 24 volts ac circuit. +10 volts dc input from power source to wire feeder with respect to socket D.

  • Page 18: Removing Safety Collar And Adjusting Boom

    4-8. Removing Safety Collar And Adjusting Boom Tools Needed: 1-1/8 in 4-9. Gun Recommendation Table Process GMAW − Hard or Cored Wires FCAW − Self-Shielding Wires 4-10. Wire Type, Size, And Feed Speed Capability Table Motor Speed Wire Type Standard Standard Standard Optional High...

  • Page 19: Installing And Threading Welding Wire

    4-11. Installing And Threading Welding Wire Install wire spool. Ad- just tension nut so wire is taut when wire feed stops. Pressure Adjust Install drive rolls. NONCONDUCTIVE SURFACE No Wire Slip 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 with-...

  • Page 20: Setting Internal Dip Switches

    4-12. Setting Internal DIP Switches Right Side Motor Control Board PC1 Position Settings And Results For DIP Switch S1 On PC1 And PC101 Automatic Run-In (ON) Automatic Run-In (OFF) (Factory Default) S1-1 And S1-2 Off = Run-In speed is set using On = Run-In speed is approximately 1/2 weld wire potentiometer P1 located on Motor...

  • Page 21: Optional Equipment Dip Switch Settings

    4-13. Optional Equipment DIP Switch Settings PC60 Digital Meter Functions Standard Standard High Speed Motor Motor Motor Inches/Minute Meters/Minute Inches/Minute Remove wrapper. Digital Meter Board PC60 Meter Board Switch S2 Install wrapper when finished. High Speed Motor Meters/Minute Tools Needed: 1/4 in 803 188 OM-1500-13 Page 17...

  • Page 22: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Power Switch 5-2. Left/Right Select Switch 5-3. Jog/Purge Pressing the Jog/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.

  • Page 23: Trigger Hold Switch

    5-4. Trigger Hold Switch 5-5. Voltage Control And Digital Meters Trigger Hold Switches Trigger hold allows the operator to weld without holding the gun trigger. To use the trigger hold function, place the trigger hold switch in the On position. The operator must hold the trig- ger for a minimum of 2 seconds, but not longer than 6 seconds be-...

  • Page 24: Section 6 − Maintenance & Troubleshooting

    SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance 3 Months Replace unreadable labels. Replace Check cracked 14-pin cord. parts. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. Notes OM-1500-13 Page 20 Y Disconnect power before maintaining. Clean and tighten weld...

  • Page 25: Diagnostics

    6-2. Diagnostics Left Side Motor Control Left Side Motor Control Board PC101 Right Side Motor Control Right Side Motor Control Board PC1 Dual Board PC70 *Since blink On time and blink Off time are equal in a four-blink cycle, the four−blink sequence appears as constant blinking. Error Indications Error conditions are indicated by LED3 on PC1, PC101, PC70 or on display if meter op-...

  • Page 26: Troubleshooting

    6-3. Troubleshooting Trouble Wire feeds, shielding gas flows, but Check cable connections. Check cables for continuity, and repair or replace cables if necessary electrode wire is not energized. (see Section 4-5). Wire feeder is on, display does not light Check and reset circuit breaker at welding power source. up, motor does not run, gas valve and welding power source contactor do not pull in.
  • Page 27 Notes OM-1500-13 Page 23...

  • Page 28: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram OM-1500-13 Page 24...
  • Page 29 204 716-B OM-1500-13 Page 25...

  • Page 30: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 803 189-C Figure 8-1. Main Assembly OM-1500-13 Page 26...
  • Page 31 Item Dia. Part Mkgs....See Note ..... 201 319 .
  • Page 32 Item Dia. Part Mkgs....204 722 ..... 134 464 .
  • Page 33 Item Dia. Part Mkgs..R1,101 ..073 562 . . . 17 R1,101,70,170 224 597 ....204 723 .
  • Page 34 Hardware is common and not available unless listed. ST-142 306-H Figure 8-3. Boom Assembly OM-1500-13 Page 30...
  • Page 35 Item Part Figure 8-3. Boom Assembly (Fig 8-1 Item 14) ... . 010 313 Pin, Cotter Hair .072 X 1.437 ... . 010 910 Washer, Flat Stl Sae .375 .
  • Page 36 Hardware is common and not available unless listed. See Table 8-1 For Drive Roll & Wire Guide Kits Item Dia. Part Mkgs. Figure 8-4. Drive Assembly, Wire (Figure 8-1 Item 26) ....010 668 .
  • Page 37 Item Dia. Part Mkgs. Figure 8-4. Drive Assembly, Wire (continued) ..... 184 136 ....155 098 .
  • Page 38 Item Part Figure 8-5. Support, Hub & Reel (Fig 8-1 Item 11) ..058 427 RING, retaining spool ..136 684 NUT, stl slflkg hex reg .625-11 w/nyl insert .
  • Page 39 Table 8-1. Drive Roll and Wire Guide Kits Wire Size Metric Fraction .023-.025 in. 0.6 mm 150 993 149 518 .030 in. 0.8 mm 150 993 149 518 .035 in. 0.9 mm 150 993 149 518 .040 in. 1.0 mm 150 993 149 518 .045 in.
  • Page 40 Notes...
  • Page 41 Notes...
  • Page 42 Notes...
  • Page 43 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.

  • Page 44: Options And Accessories

    File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2006 Miller Electric Mfg. Co. 2006−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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