Miller S-74 MPa Plus Owner's Manual
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Miller S-74 MPa Plus Owner's Manual

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S-74 MPa Plus
CE
OM-273245N
2021−06
Processes
MIG (GMAW) Welding
MIG (GMAW-P) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
Aluminum Push/Pull Capable
File: MIG (GMAW)

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  • Page 1 OM-273245N 2021−06 Processes MIG (GMAW) Welding MIG (GMAW-P) Welding Flux Cored (FCAW) Welding (Gas- And Self-Shielded) Description Wire Feeder Aluminum Push/Pull Capable S-74 MPa Plus For product information, File: MIG (GMAW) Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 8 − PROGRAMMING ............. . . 8-1.
  • Page 5 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. LLC, 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s), Commission Regulation(s) and Standard(s).
  • Page 6 DECLARATION OF CONFORMITY for United Kingdom (UKCA marked) products. MILLER Electric Mfg. LLC, 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Regulation(s) and Standard(s).

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2020−02 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 8 D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

  • Page 9: Additional Hazards For Installation, Operation, And Maintenance

    D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 10: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2020−02_fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...

  • Page 14: Proposition Californienne 65 Avertissements

    D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.
  • Page 16 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Safe63 2012−06 Do not weld on drums or any closed containers. Safe16 2017−04 Do not remove or paint over (cover) the label. Safe20 2017−04 Drive rolls can injure fingers.

  • Page 17: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Rated Welding Amperes Output Current Direct Current (DC) Program Duty Cycle Degree Of Protection Preflow Time Primary Current Hertz Line Connection Wire Type Set Up Conventional Arc Length Increase Load Voltage Process...

  • Page 18: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2.
  • Page 19 D. China EEP Hazardous Substance Information   ‡ China EEP Hazardous Substance Information Ö Hazardous Substance Component Name × (if applicable) PBDE Ö Brass and Copper Parts Coupling Devices Switching Devices Ö Cable and Cable Accessories Batteries SJ/T 11364 This table is prepared in accordance with China SJ/T 11364.

  • Page 20: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Selecting A Location Do not put feeder where welding wire hits cylinder. Wire feeder shown is repre- sentative only and may not reflect actual unit. Wire Feeder Wire Spool/Reels Gas Cylinder w/Hose And Regulator (Customer Supplied) Shielding gas pressure not to exceed 100 psi (689 kPa).

  • Page 21: Equipment Connection Diagrams

    5-2. Equipment Connection Diagrams Welding Power Source Select welding power source according to Section 6-11. Contactor Control/Power Cord Positive (+) Weld Cable Negative (−) Weld Cable Workpiece Welding Gun Wire Feeder Gas Hose Gas Cylinder and Regulator (Customer Supplied) Shielding gas pressure not to exceed 100 psi (689 kPa).

  • Page 22: Rear Panel Connections And Rotating Drive Assembly

    5-3. Rear Panel Connections And Rotating Drive Assembly Turn off power before connecting to weld terminal or receptacle. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. 14-Pin Control Cable - 15 Ft (4.6 m) Shielding Gas Valve Fittings Requires fitting with 5/8-18 right-...

  • Page 23: 14-Pin Plug Information For Connecting Wire Feeder To Power Source

    5-4. 14-Pin Plug Information For Connecting Wire Feeder To Power Source Pin* 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 24: Installing Welding Gun

    5-6. Installing Welding Gun Power Clamp Knob Gun Locking Tab Power Pin Groove Gun Connection End Installing gun with Accu-Mate connection Loosen power clamp knob to allow power pin of gun to clear the gun locking tab. Push power pin into power clamp as far as possible to align the groove in the power pin of the gun with the gun locking tab.

  • Page 25: Installing And Threading Welding Wire

    5-7. Installing And Threading Welding Wire Install wire guides and Install wire spool. Adjust tension nut so 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...

  • Page 26: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Power Switch Power Switch Ref. 246039-C 6-2. Jog/Purge Switch Jog/Purge Switch Ref. 246039-C Pressing the Jog/Purge switch allows the op- mum of two minutes. If the gun trigger is still control when the unit is jogging wire. The erator to jog wire without energizing the weld activated after two minutes, the jog opera- unit displays jog speed when the unit is be-...

  • Page 27: Front Panel Controls

    6-3. Front Panel Controls Ref. 271 487-A Left Display (See Section 6-4) Adjust Control Right Setup Push Button (See Section 6-7) (See Section 6-6) Right Display (See Section 6-5) Start Push Button (See Section 6-8) Program Select Push Button Adjust Control Left (See Section 6-6) (See Section 6-10) Crater Push Button (See Section 6-9) Notes...

  • Page 28: Left Display

    6-4. Left Display Left Display particular power source, see Section 6-11 The unit displays both preset and actual arc − Power Source Selection Menu. voltage. When the unit is in a welding state, Arc Length LED actual arc voltage is displayed. Volts LED Left Display See Section 8-2 for selection of arc length...

  • Page 29: Adjust Control Left/Right

    6-6. Adjust Control Left/Right Adjust Control Use Adjust control to change vari- ous parameters or menu items. Use left control to adjust volts or arc length. Use right control to adjust amper- age or wire feed speed. 6-7. Setup Push Button Setup Push Button Setup LED When the Setup button is pressed,...

  • Page 30: Power Source Selection Menu

    6-11. Power Source Selection Menu Left Display Right Display 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.

  • Page 31: Operational Terms

    6-12. Operational Terms The following is a list of terms and their definitions as they apply to this wire feeder: General Terms: 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 postflow. Weld Program A group of sequences that make up a weld cycle.

  • Page 32: Section 7 − Setting Sequence Parameters

    SECTION 7 − SETTING SEQUENCE PARAMETERS 7-1. Sequence Parameters In A Program Sequence Parameters Volts Seconds Inches 1. Preflow 0-5.0 2. Run-In x0.1-x1.00 3. Start .1-.5 4. Weld 0-100.0 5. Crater 0.00-5.00 6. Postflow 0.0-10.0 7. Retract 0.0-1.5 X = Setting available. Weld Time Crater Retract...

  • Page 33: Section 8 − Programming

    SECTION 8 − PROGRAMMING 8-1. Setup Menu To enter the SETUP MENU press and re- make this function operational. If gun trig- Preflow (PRE) − The amount of time that lease the SETUP button. The SETUP ger is released during welding the unit goes the shielding gas will flow after the trigger MENU INDICATOR and the SETUP into trigger hold - pressing and holding trig-...

  • Page 34: Setup Menu Level 2

    8-2. Setup Menu Level 2 To enter the SETUP MENU LEVEL 2 press process. If the power source weld process When set to (NO), (PROF) will not appear and hold the SETUP button. The SETUP is set to PULSED MIG, the minimum in the Setup Menu.

  • Page 35: Setting A Start Sequence In Synergic Pulse

    8-3. Setting A Start Sequence In Synergic Pulse To turn on a Start sequence, press the To exit the START MENU, press and re- Example: If the weld arc length is set to 50 START button. START lease the START button. and ARC.L is X0.50, the Start Arc Length is INDICATOR will illuminate indicating Start Items that can be adjusted in this menu are:...

  • Page 36: Setting A Start Sequence In Non−Synergic Pulse Or Mig

    8-4. Setting A Start Sequence In Non−Synergic Pulse Or MIG To turn on a Start sequence, press the Knob to change menu item values shown When MIG is selected in Setup Menu START button. START in the RIGHT DISPLAY. Level 1 the start arc length setting will INDICATOR will illuminate indicating Start be replaced by Start Voltage (VOLT).

  • Page 37: Setting A Crater Fill Sequence In Synergic Pulse

    8-5. Setting A Crater Fill Sequence In Synergic Pulse To turn on Crater Fill, press the CRATER lease the CRATER button. When the PULS option in the SETUP button. The CRATER ON INDICATOR will MENU LEVEL 2 is set to VOLT, the illuminate indicating Crater Fill is active.

  • Page 38: Setting A Crater Fill Sequence In Non−Synergic Pulse Or Mig

    8-6. Setting A Crater Fill Sequence In Non−Synergic Pulse Or MIG To turn on Crater Fill, press the CRATER To exit the CRATER MENU press and re- ting is dependent on the power source or button. The CRATER ON INDICATOR will lease the CRATER button.

  • Page 39: Profile Pulse

    8-7. Profile Pulse Profile Pulse optimizes Aluminum weld Profile Pulse Items that can be adjusted in ting is (X0.00 to X0.30). Example: If the wire bead appearance by producing welds with the Setup Menu are: feed speed is 200 and (P.WFS) is set to consistently spaced ripple patterns, similar (X0.10), the wire feed speed will alternate Profile Pulse ON/OFF (PROF) −...

  • Page 40: Section 9 − Maintenance & Troubleshooting

    SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Routine Maintenance Disconnect power before maintaining. n = Check ~ = Clean l = Replace Every Spool of Wire or Wire Change n~ Gun Liner Every Months l Unreadable Labels ~ Weld Terminals nl Weld Cable l Cracked Parts n 14-Pin Cord...

  • Page 41: Troubleshooting

    9-3. Troubleshooting Disconnect power before troubleshooting. Trouble Remedy Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 5-6). Pressing gun trigger does not energize feeder. Shielding gas does not flow and Have nearest Factory Authorized Service Agent check optional water flow switch, if applicable. wire feeder does not feed.

  • Page 42: Section 10 − Electrical Diagram

    SECTION 10 − ELECTRICAL DIAGRAM Figure 10-1. Circuit Diagram OM-273245 Page 36...
  • Page 43 Left Gun Trigger Connector Right Gun Trigger Connector 244 221-G OM-273245 Page 37...

  • Page 44: Section 11 − Parts List

    SECTION 11 − PARTS LIST Hardware is common and not available unless listed. Fig. 11-3 22 − Fig. 11-2 246042-D Figure 11-1. Main Assembly OM-273245 Page 38...
  • Page 45 Item Part Description Quantity Figure 11-1. Main Assembly ....159647 Insulator, Motor Clamp ......... . .
  • Page 46 Hardware is common and not available unless listed. 10 11 246043-F Figure 11-2. Control Box Item Dia. Part Mkgs. Description Quantity Figure 11-2. Control Box (Figure 11-1 Item 22) ....235211 Wrapper, Feeder (Includes) .
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 11-2. Control Box (Figure 11-1 Item 22) (Continued) ....200295 Switch, Rocker Spdt 15A 12V (On)−Off−(On) .
  • Page 48 Hardware is common and not available unless listed. See Table 11-1 For Drive Roll & Wire Guide Kits 245244-F Figure 11-3. Drive Assembly, Wire Item Dia. Part Mkgs. Description Quantity Figure 11-3. Drive Assembly, Wire (Figure 11-1 Item 4) ..... 244585 Drive Assy, Wire S/L 4 Roll W/Tach Accu−Mate (Items 1-38) .
  • Page 49 Item Dia. Part Mkgs. Description Quantity Figure 11-3. Drive Assembly, Wire (Continued) ....133739 ..Washer, Flat Buna .375 Id X .625 Od X .062Thk .
  • Page 50 Table 11-1. Drive Roll And Wire Guide Kits OM-273245 Page 44...
  • Page 51 Effective January 1, 2021 (Equipment with a serial number preface of NB or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions TIG Torches (No Labor) below, Miller Electric Mfg.
  • Page 52 Contact the Delivering Carrier to: 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2021 Miller Electric Mfg. LLC 2021−01...

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