Miller S-74 MPa Plus Technical Manual Download Page 8

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TM-273245 Page 4

S-74 MPa Plus

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Safe63 2012

−

Do not weld on drums or any closed containers.

Safe16 2017

−

Do not remove or paint over (cover) the label.

Safe20 2017

−

Drive rolls can injure fingers.

Safe32 2012

−

Welding wire and drive parts are at welding voltage during operation

−

keep hands and metal objects away.

Safe33 2017

−

Environmental Protection Use Period (China)

Safe123 2016

−

Wear hat and safety glasses. Use ear protection and button shirt

collar. Use welding helmet with correct shade of filter. Wear complete

body protection.

Safe66 2012

−

Become trained and read the instructions before working on the

machine or welding.

Safe65 2012

−

Notes

Summary of Contents for S-74 MPa Plus

Page 1: ...G135049U File MIG GMAW Processes Description MIG GMAW Welding MIG GMAW P Welding Flux Cored FCAW Welding Gas And Self Shielded Wire Feeder Aluminum Push Pull Capable For product information Owner s Ma...

Page 2: ...e 11 4 6 Installing Welding Gun 12 4 7 Installing And Threading Welding Wire 13 SECTION 5 OPERATION 14 5 1 Power Switch 14 5 2 Jog Purge Switch 14 5 3 Front Panel Controls 15 5 4 Left Display 16 5 5 R...

Page 3: ...s On User Interface Board PC2 39 9 7 User Interface Board PC2 Testing Information 40 9 8 User Interface Board PC2 Test Point Values 40 9 9 14 Pin Filter Board PC5 Testing Information 42 9 10 14 Pin Fi...

Page 4: ......

Page 5: ...energized D Insulate yourself from ground by standing or working on dry insulat ing mats big enough to prevent contact with the ground D Do not leave live unit unattended D If this procedure requires...

Page 6: ...ation regularly checked and maintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of inte...

Page 7: ...al recycling office or your local distributor for further information Safe37 2017 04 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves Safe2 2017 04 Pr...

Page 8: ...s can injure fingers Safe32 2012 05 Welding wire and drive parts are at welding voltage during operation keep hands and metal objects away Safe33 2017 04 Environmental Protection Use Period China Safe...

Page 9: ...Set Up Increase Process Time Postflow Time Gas Input Purge By Gas Constant Voltage I2 Rated Welding Current Program Preflow Time Line Connection U2 Conventional Load Voltage Wire Feed Cold Jog Inch To...

Page 10: ...Spool Weight 60 lb 27 kg 100 Volts 600 Amperes 100 Duty Cycle Length 27 in 686 mm Width 12 1 2 in 318 mm Height 14 in 356 mm 48 lb 21 8 kg See Section 4 5 for detailed information on wire type wire s...

Page 11: ...J T 11364 0 This table is prepared in accordance with China SJ T 11364 O 5 7 8 9 97 GB T26572 A Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is...

Page 12: ...shown is repre sentative only and may not reflect actual unit 1 Wire Feeder 2 Wire Spool Reels 3 Gas Cylinder w Hose And Regulator Customer Supplied Shielding gas pressure not to exceed 100 psi 689 k...

Page 13: ...lding power source according to Section 5 11 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...

Page 14: ...Fittings Requires fitting with 5 8 18 right hand threads Connect customer supplied gas hose 3 Weld Cable Terminal 4 Weld Cable 5 Drive Assembly 6 Drive Assembly Rotation Knob To rotate the drive assem...

Page 15: ...DC output signal from wire feeder to power source with respect to socket D H Voltage feedback 0 to 10 volts DC 1 volt per 10 arc volts F Current feedback 0 to 10 volts DC 1 volt per 100 amperes L 0 to...

Page 16: ...otate gun locking tab 180 degrees This pre vents the locking tab from extend ing into the power pin gun connec tion Push power pin into power clamp as far as possible Secure gun by tightening power cl...

Page 17: ...l gun and pressure blocking clips do not adjust pressure For aluminum wire set pressure indicator scale as light as possible To adjust drive roll pressure hold nozzle about 2 in 51 mm from nonconducti...

Page 18: ...the unit will perform a jog operation for a maxi mum of two minutes If the gun trigger is still activated after two minutes the jog opera tion is terminated to prevent complete des poolingof the wire...

Page 19: ...t Display See Section 5 5 3 Adjust Control Left See Section 5 6 4 Adjust Control Right See Section 5 6 5 Program Select Push Button See Section 5 10 6 Setup Push Button See Section 5 7 7 Start Push Bu...

Page 20: ...is in a welding state actual wire feed speed is displayed for the active welding sequence 2 Wire Feed Speed LED 3 Amps LED The LEDs below the display illuminate to indi cate which value is being shown...

Page 21: ...ore advanced setup features 5 8 Start Push Button 2 1 1 Start Push Button 2 Start LED Press button to activate deactivate start parameters LED is on when start is enabled Press and hold but ton for 1...

Page 22: ...in welding When turning off the feed er the default power source will be retained Next Time Feeder Is Turned On The feeder will display the last se lected default power source The operator has three s...

Page 23: ...rc length or voltage setting STD Basic trigger function weld sequence starts when the trigger is pressed and ends when the trigger is released Trigger Hold Trigger function allowing the operator to we...

Page 24: ...Time Start Time Preflow Weld Time Crater Time Postflow Start Time Time Postflow Crater Weld Run In Preflow Sequence End Volts IPM Seconds 4 Weld 5 Crater 6 Postflow 2 Run In 0 100 0 0 00 5 00 0 0 10...

Page 25: ...d or the trigger has been released whichever occurs first The spot time is reset when the trigger is re leased Remote Process Select For MIG MIG operation the Left Display always shows Voltage For Pul...

Page 26: ...o match the power source display When set to VOLT the preset voltage set point will be shown in the Left Display with the VOLTS INDICATOR illuminated When set to ARC L the preset arc length will be sh...

Page 27: ...stable Start Wire Feed Speed WFS Sets the wire feed speed used during the Start Time This setting is a percentage of the wire feed speed the unit is set to for welding Range of this setting is from X0...

Page 28: ...sted in this menu are Start Wire Feed Speed WFS Sets the wire feed speed used during the Start Time Range of this setting is from 70 to 780 IPM Start Arc Length ARC L Sets the arc length during the St...

Page 29: ...percentage of the wire feed speed the unit is set to for welding Range of this setting is from X0 30 to X1 00 Example If the weld wire feed speed is 200 and WFS is X0 50 the Crater Wire Feed Speed is...

Page 30: ...Fill wire feed speed Crater Arc Length ARC L Sets the arc length during the crater time Range of this setting is from 0 0 to 100 0 and the level is set to match crater WFS When MIG is selected in Setu...

Page 31: ...X0 00 to X0 30 Example If the wire feed speed is 200 and P WFS is set to X0 10 the wire feed speed will alternate between 180 and 220 ipm Profile Pulse Arc Length P AL Sets an arc length correction f...

Page 32: ...d cycle 8 Motor Board PC1 Controls wire speed by changing the pulse width modulation signal wider or narrower pulses mean ing more or less voltage to motor after comparing motor speed feedback signals...

Page 33: ...eck trigger filter board PC8 RC18 and replace if necessary see Section 9 11 Check motor board PC1 RC8 and RC and replace if necessary see Section 9 4 Motor does not run when Jog switch is pressed Chec...

Page 34: ...ometer board PC51 see Section 9 13 Check motor board PC1 and connections and replace if necessary see Section 9 4 Limited wire speed control Check push pull gun wire speed potentiometer and control ca...

Page 35: ...r replace hose Clear blockage in welding gun See gun Owner s Manual Welding arc is too cold regardless of voltage control preset Check extension cord and 14 pin plug connections If secure check cord f...

Page 36: ...s 9 2 Troubleshooting Circuit Diagram For S 74 MPa Plus See Section 9 11 for PC8 information V2 V1 See Section 9 4 for PC1 information See Section 9 9 for PC5 information V9 V10 V11 V12 V13 V14 V7 V8...

Page 37: ...mps current feedback V6 1 volt 10 volts DC voltage feedback V7 0 to 10 volts DC command voltage arc length V8 0 to 10 volts DC wirefeed speed command V9 15 volts DC when triggered V10 15 volts DC when...

Page 38: ...MPa Plus 9 3 Location Of Circuit Boards 1 Motor Board PC1 See Section 9 4 2 User Interface Board PC2 See Section 9 7 3 14 Pin Filter Board PC5 See Section 9 9 4 Trigger Filter Board PC8 See Section 9...

Page 39: ...Plus Notes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL...

Page 40: ...formation RC12 RC11 RC1 RC4 Test Equipment Needed Be sure plugs are secure before testing See Section 9 5 for specific values during testing 1 Motor Board PC1 No testing required for remain ing plugs...

Page 41: ...to RC1 15 8 Gun command potentiometer 0 5 volts DC reference to RC1 15 9 Gun command reference 5 volts DC reference to RC1 15 10 Gun motor 0 24 volts DC reference to RC1 12 11 SW Ref 12 Gun motor ref...

Page 42: ...nce to RC6 4 DGND 2 USB DP 3 USB DM 4 DGND RC8 1 Motor common 2 Gas valve common 3 Gas Valve 0 volts AC 24 volts AC when purged triggered reference to RC8 2 4 Motor 2 volts DC to 24 volts DC reference...

Page 43: ...Test 1 On Indicates 15 volts DC present on motor board PC1 with respect to DC circuit common Off If LED1 and LED2 are on power supply circuits on motor board are working properly If LED1 and LED2 are...

Page 44: ...cure before testing See Section 9 8 for specific values during testing 1 User Interface Board PC2 1 246913 C 272234 B RC100 9 8 User Interface Board PC2 Test Point Values a Tolerance 10 unless specifi...

Page 45: ...Plus Notes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL...

Page 46: ...14 Pin Filter Board PC5 Testing Information Test Equipment Needed Be sure plugs are secure before testing See Section 9 10 for specif ic values during testing 1 14 Pin Filter Board PC5 1 246913 C 244...

Page 47: ...mode Process Select 3 5 volts DC in MIG 2 5 volts DC in pulse reference to RC30 4 4 14 Pin N wire feed speed common 5 14 pin D Power Source Common 6 14 pin H Voltage Feedback 1V 10V reference to RC30...

Page 48: ...Testing Information Test Equipment Needed Be sure plugs are secure before testing See Section 9 12 for specif ic values during testing 1 Trigger Filter Board PC6 No testing required for remain ing pl...

Page 49: ...C RC18 1 Gun motor tach 3 3 kHz to 42 kHz or 1 6 volts DC when running reference to RC8 15 2 Not used 3 Left trigger signal 0 volts DC 15 volts DC when triggered 4 Trigger signal AlumaPro 0 volts DC 1...

Page 50: ...motor control board RC1 1 to RC1 16 6 Push pull gun trigger 15 volts DC 7 Push pull gun trigger 15 volts DC when push pull gun is triggered 8 Gun command reference 5 volts DC 9 Gun command common 10...

Page 51: ...Circuit common Pin 3 15 volts DC input 4 Encoder Disk Remove disk and clean using de natured solvent 5 Optical Coupler OC50 Clean inside surface with cotton swab dipped in denatured alcohol solvent Ce...

Page 52: ...also occurs if the purge switch is held when the feeder is powered up The error may be cleared by releasing the purge switch COOL ERR Indicates a water flow switch error A water flow switch error occ...

Page 53: ...tor for more information The following is a list of all diagrams for models covered by this manual Model Serial Or Style Number Circuit Diagram Wiring Diagram S 74 MPa Plus MG135049U and following 244...

Page 54: ...TM 273245 Page 50 S 74 MPa Plus Figure 11 1 Circuit Diagram For S 74 MPa Plus Eff w Serial No MG135049U And Following...

Page 55: ...TM 273245 Page 51 S 74 MPa Plus 244221 G Left Gun Trigger Connector Right Gun Trigger Connector...

Page 56: ...Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA Canada FAX 920 735 4134 International FAX 920 735 4125 For International...

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