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Miller Electric S-74S - page 1
S-74S, S-74D Processes Description MIG (GMA W) W elding Flux Cored (FCA W ) Welding (Gas- And Self-Shielded) Wire Feeder OM-1500-10 207 748K 2006 − 01 Visit our website at www.MillerWelds.com File: MIG (GMA W) ...
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Miller Electric S-74S - page 2
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 .Mille ...
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Miller Electric S-74S - page 3
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . ...
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Miller Electric S-74S - page 4
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 . Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r .l. Phon ...
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Miller Electric S-74S - page 5
OM-1500-10 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety me ...
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Miller Electric S-74S - page 6
OM-1500-10 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching ...
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Miller Electric S-74S - page 7
OM-1500-10 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. ...
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Miller Electric S-74S - page 8
OM-1500-10 Page 4 1-5. Principal Safety Standards Safety i n W elding, 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 W elding and Cut- ting of Containers and Piping , American Welding Society Standard A W ...
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Miller Electric S-74S - page 9
OM-1500-10 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les ut ilisés Sy mbole graphique d’avert iss ement ! Att ention ! Cette pro - cédur e comporte d es r i sques poss ib ...
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Miller Electric S-74S - page 10
OM-1500-10 Page 6 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. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la pe ...
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Miller Electric S-74S - page 11
OM-1500-10 Page 7 2-3 . Dange rs suppléme ntaire s en r e lation avec l’installa tion, le f onctionne ment et l a maintena nce 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 ...
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Miller Electric S-74S - page 12
OM-1500-10 Page 8 2-5. Princi pales no rmes de sécurit é Safety in W elding, 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 fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W el ...
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Miller Electric S-74S - page 13
OM-1500-10 Page 9 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! Watch 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 . 1 Electric s ...
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Miller Electric S-74S - page 14
OM-1500-10 Page 10 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 5-2. 3-3. Symbols And Definitions Some symbols are found only on CE products. Note A Amperes V V olts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz P ...
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Miller Electric S-74S - page 15
OM-1500-10 Page 1 1 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 Dimensions W eight 24 V olts ac Single-Phase 10 Amperes 50/60 Hertz Constant V oltage (CV) DC With 14-Pin And Contactor Control Standard: 50 T o 780 i ...
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Miller Electric S-74S - page 16
OM-1500-10 Page 12 5-2. Rear Panel Connections And Rotating Drive Assembly 802 824-A / 802 825-A 2 3 4 1 14-Pin Control Cable - 10 ft (3.0 m) 2 Shielding Gas V alve Fitting Connect customer-supplied gas hose with 5/8-18 right-hand threads. . Shielding gas pressure not to exceed 90 PSI (620 kPa). 3 Weld Cable T erminal 4 Weld Cable 5 Drive Assembly ...
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Miller Electric S-74S - page 17
OM-1500-10 Page 13 5-3. 14-Pin Plug PLG12 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. D M G E F ...
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Miller Electric S-74S - page 18
OM-1500-10 Page 14 5-6. Installing And Threading W elding Wire Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / S-0627-A T ools Needed: . 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 a s possible to drive rolls without touching. Install gun. ...
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Miller Electric S-74S - page 19
OM-1500-10 Page 15 5-7. Setting Internal DIP Switches Position Settings And Results For DIP Switch S1 On PC1 On = Current detect over- ride. For welding power sources that don’t provide current feedback through the 14-pin receptacle. Run- in is inactive. Off = Current must be detected from power sources that provide current feedback through the 1 ...
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Miller Electric S-74S - page 20
OM-1500-10 Page 16 T ools Needed: 1/4 in 5-8. Equipment DIP Switch Settings (For Models With Meters Only) 12 3 45 Or Or High Speed Motor Meters/Minute High Speed Motor Inches/Minute Standard Motor Meters/Minute Standard Motor Inches/Minute Digital Meter Functions 12 3 45 12 3 45 12 3 45 Ref. 802 946 Remove wrapper . Install wrapper when finished. ...
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Miller Electric S-74S - page 21
OM-1500-10 Page 17 SECTION 6 − OPERA TION 6-1. Power Switch 1 Power Switch 1 802 827-A 6-2. Jog/Purge 1 802 828-A 2 1 Jog/Purge Push Button 2 Wire Speed Control 3 Gun Trigger Receptacle Pressing the Jog/Purge switch al- lows the operator to jog wire without energizing the weld power or gas valve circuit. • The wire feeder can also be jogged by ...
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Miller Electric S-74S - page 22
OM-1500-10 Page 18 6-3. T rigger Hold Switch 1 T rigger Hold Switch Trigger hold allows the operator to weld with- out holding the gun trigger . • T o use the trigger hold function, place the trigger hold switch in the On position. • T he operator must hold the trigger for a mini- mum of 2 seconds, but not longer than 6 seconds before releasing ...
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Miller Electric S-74S - page 23
OM-1500-10 Page 19 SECTION 7 − MAINTENANCE 7-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. Check 14-pin cord. Check gas hose and fittings. Check gun cable. Replace cracked parts. 6 Months Blow out or vacuum inside. During he ...
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Miller Electric S-74S - page 24
OM-1500-10 Page 20 7-2. Diagnostics • Error Indications Error conditions are indicated by LED3 on PC 1 or on display (on models with meters). T o view LED3, turn Off unit, remove wrapper , an d turn unit On. LED3 is most easily observed from the left side of the unit. The LED blinks in a 2.5 second cycle. The number of blinks in this period indic ...
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Miller Electric S-74S - page 25
OM-1500-10 Page 21 7-3. T roubleshooting Y Disconnect power before troubleshooting T rouble Remedy Wire feeds, shielding gas flows, but electrode wire is not energized. Check cable connections. Check cables for continuity , and repair or replace cables if necessary (see Section 5-2). Wire feeder is on, display does not light up, motor does not run, ...
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Miller Electric S-74S - page 26
OM-1500-10 Page 22 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram 202 246-C ...
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Miller Electric S-74S - page 27
OM-1500-10 Page 23 Notes ...
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Miller Electric S-74S - page 28
OM-1500-10 Page 24 SECTION 9 − P ARTS LIST 802 943 . Hardware is common and not available unless listed. Fig 9-2 21 Fig 9-3 4 1 2 6 14 15 16 17 18 19 20 5 7 8 9 10 11 12 11 10 13 3 Figure 9-1. Main Assembly ...
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Miller Electric S-74S - page 29
OM-1500-10 Page 25 Item No. Item No. Part No. Description Quantity Figure 9-1. Main Assembly Part No. Description Quantity 1 159 647 Insulator , Motor Clamp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 159 646 Clamp, Motor Base 1 . . . . . . . . . . . . . . . . . . . ...
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Miller Electric S-74S - page 30
OM-1500-10 Page 26 802 945-D . Hardware is common and not available unless listed. 2 5 6 7 8 9 8 7 10 11 12 13 14 15 16 17 18 19 20 23 24 25 26 27 22 28 4 21 3 1 29 Figure 9-2. Control Box Item No. S-74S S-74D Figure 9-2. Control Box (Figure 9-1 Item 21) Diagram marking Part No. Description Quantity Model 1 200 555 Wrapper , Feeder 1 1 . . . . . . ...
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Miller Electric S-74S - page 31
OM-1500-10 Page 27 Item No. Diagram marking Part No. Description Quantity Model S-74S S-74D Figure 9-2. Control Box (Figure 9-1 Item 21) 21 213 134 Knob, Encoder 1.670 Dia X .250 Id Push On W/Spring 0 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1 19 951 Blank, Snap-in Nyl .437 Mtg Hole Black 1 0 . . . . . . . . . . . . . . ...
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Miller Electric S-74S - page 32
OM-1500-10 Page 28 See T able 9-1 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 9-3. Drive Assembly , Wire Item No. Diagram marking Part No. Description Quantity Model ...
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Miller Electric S-74S - page 33
OM-1500-10 Page 29 Item No. Diagram marking Part No. Description Quantity Model S-74S S-74D Figure 9-3. Drive Assembly , Wire (Continued) 203 631 Pressure Arm, S/L & V ert S/R 4 Roll (Consisting Of) 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 203 641 W asher , Flat Indicator Spring T ension 2 2 . . . . . . ...
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Miller Electric S-74S - page 34
OM-1500-10 Page 30 UC-GROOVE T able 9-1. Drive Roll And Wire Guide Kits .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 1 ...
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Miller Electric S-74S - page 35
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 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. Support Need fast answers to the tough welding questions? Contact your distributor . The expe ...
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Miller Electric S-74S - page 36
PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 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 − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 9 20-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters − ...
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