Instruction/ maintenance manual of the product D-74DX Miller Electric
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D-74DX Processes Description MIG (GMAW) W elding Flux Cored (FCA W ) W elding (Gas- And Self-Shielded) Wire Feeder OM-1500-7 204 129H 2007 − 07 Visit our website at www.
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 .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 .
OM-1500-7 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 .
OM-1500-7 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.
OM-1500-7 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.
OM-1500-7 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.
OM-1500-7 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.
OM-1500-7 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.
OM-1500-7 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.
OM-1500-7 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.
OM-1500-7 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 .
OM-1500-7 Page 10.
OM-1500-7 Page 1 1 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 .
OM-1500-7 Page 12 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 5-3. 3-3. WEEE Label (For Products Sold Within The EU) Do not discard product (where ap- plicable) with general waste.
OM-1500-7 Page 13 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 Di.
OM-1500-7 Page 14 5-2. Equipment Connection Diagrams 1 W elding Power Source 2 Contactor Control/Power Cord 3 Positive (+) Weld Cable 4 Negative ( − ) W eld Cable 5 W orkpiece 6 Welding Gun 7 Wire Feeder 8 Gas Hose 9 Gas Cylinder and Regulator (Customer Supplied) .
OM-1500-7 Page 15 5-3. Rear Panel Connections And Rotating Drive Assembly 803 067 / 802 825-A 2 1 14-Pin Control Cable - 10 Ft (3.0 m) 2 Shielding Gas V alve Fittings Requires fitting with 5/8-18 right- hand threads. Connect customer- supplied gas hose.
OM-1500-7 Page 16 5-4. 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.
OM-1500-7 Page 17 5-7. Installing And Threading W elding Wire Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / S-0627-A T ools Needed: . For best wire feeding performance, be sure that the outlet cable has the proper size liner for the welding wire size being used.
OM-1500-7 Page 18 5-8. 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.
OM-1500-7 Page 19 5-9. 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.
OM-1500-7 Page 20 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.
OM-1500-7 Page 21 6-4. Jog/Purge Switch 1 Ref. 803 053 2 3 1 Jog/Purge Switch 2 Adjust Control 3 Gun Trigger Receptacle 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.
OM-1500-7 Page 22 6-5. 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 6-7 See Section 6-8 See Se.
OM-1500-7 Page 23 6-6. 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.
OM-1500-7 Page 24 6-8. Lower Display 2 Wire Speed Amps 1 5 4 3 1 4 2 3 5 Non-CE Models CE Models 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.
OM-1500-7 Page 25 6-10. 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.
OM-1500-7 Page 26 6-12. 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 3 2 1 8 9 5 7 6 4 Non-CE.
OM-1500-7 Page 27 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”.
OM-1500-7 Page 28 OPT1 • If the Setup push button is pressed, the unit allows OPT1 to be disabled or enabled. The upper display shows “OPT1”. Lower dis- play shows “On” or “Off”. The Adjust Control is used to select either “On” or “Off”.
OM-1500-7 Page 29 SECTION 7 − SETTING SEQUENCE P ARAMETERS 7-1. Sequence Parameters In A Program . For more information on Sequence Push Button see Section 6-1 1. If time is set to zero in W eld sequence, welding continues until gun trigger is released.
OM-1500-7 Page 30 8-2. 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 .
OM-1500-7 Page 31 8-3. Diagnostics For User Defined Options 2 803 071 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.
OM-1500-7 Page 32 9-2. 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 5-2 and 5-3).
OM-1500-7 Page 33 Notes.
OM-1500-7 Page 34 SECTION 10 − ELECTRICAL DIAGRAM Figure 10-1. Circuit Diagram.
OM-1500-7 Page 35 204 144-C.
OM-1500-7 Page 36 SECTION 1 1 − P ARTS LIST 803 052-A . Hardware is common and not available unless listed. 15 19 20 22 1 2 3 17 18 16 21 Fig.1 1 − 2 4 Fig.
OM-1500-7 Page 37 Description Part No. Item No. Figure 1 1-1. Main Assembly Quantity 1 159 647 Insulator , Motor Clamp 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 159 646 Clamp, Motor Base 2 .
OM-1500-7 Page 38 803 051-C . Hardware is common and not available unless listed. 11 14 15 13 12 10 9 7 8 16 9 17 18 19 20 8 6 5 27 24 22 26 25 23 1 4 3 2 21 28 Figure 1 1-2. Control Box Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Control Box (Figure 1 1-1 Item 21) Quantity 1 204 722 Wrapper , Feeder 1 .
OM-1500-7 Page 39 Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Control Box (Continued) Quantity 21 206 765 Panel, Front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1500-7 Page 40 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.
OM-1500-7 Page 41 Description Part No. Dia. Mkgs. Item No. Figure 1 1-3. Drive Assembly , Wire (continued) Quantity 14 182 156 Spring, Cprsn 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1500-7 Page 42 .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 151 028 053 698 151 038 053 702 151 054 132 956 151 071 083 490 1/16 in.
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.
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.
An important point after buying a device Miller Electric D-74DX (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric D-74DX yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric D-74DX - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric D-74DX you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric D-74DX will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric D-74DX, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric D-74DX.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric D-74DX. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric D-74DX along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
