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Miller Electric INTEGRA 201/241 manual

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Table of contents for the manual

  • Page 1

    I 0 S Processes INTEGRA 201/241 OM-188 414C January 2000 Effective with serial number : 165 748 Description MIG (GMA W) W elding Flux Cored (FCA W) W elding Arc Welding Power Source and Wire Feeder Visit our website at www.MillerWelds.com[...]

  • Page 2

    Thank you and congratulations on choosing Miller . Now you can get the job done and get it done right. W e 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 . Like you, his customers couldn’t af [...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols for[...]

  • Page 4

    dec_con 5/97 Declaration of Conformity Manufactruer ’s Name: MILLER Europe S.P .A. Manufacturer ’s Address: Via Privata Iseo, 6/E 20098 San Giuliano Milanese, Italy Declares that this product: INTEGRA 201/241 Conforms to the following Directives and Standards: Directives Electromagnetic Compatibility Directives: 89/336/EEC Low V oltage: 73/23/E[...]

  • Page 5

    OM-188 414 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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 message. . Means “ Note ” ; not safety related. This group of symbols means W arning! [...]

  • Page 6

    OM-188 414 Page 2 Arc rays from the welding 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 a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and[...]

  • Page 7

    OM-188 414 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.[...]

  • Page 8

    OM-188 414 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However , after examining more than 500 studies spanning 17 yea[...]

  • Page 9

    OM-188 414 Page 5 SECTION 2 – INST ALLA TION 2-1. Specifications Rated Output Rated Input Amperage at Rated Output Model 100% 60% 20% Max. Open Circuit V oltage 230 V Dimension (mm) W eight (kg) 201 90 A 18.5 V 11 6 A 20 V 200 A 24 V 38 26A 2A* 310 x 540 x 957 70 241 1 15 A 20 V 150 A 21 V 240 A 26 V 41 35A 2.5A* 310 x 540 x 957 80 Wire feed spee[...]

  • Page 10

    OM-188 414 Page 6 2-3. V olt-Ampere Curves 1 Normal V olt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capa- bilities of the welding power source. Curves of other settings fall be- tween the curves shown. Model 201 Model 241 dwg. 802004, 802003 2-4. Installing Gas Supply Ref. ST-148 265-B / Re[...]

  • Page 11

    OM-188 414 Page 7 2-5. Installing Drive Roll and Wire Inlet Guide ST-150 227-C 1 Securing Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close to drive rolls as possible without touch- ing. T ighten screw . 3 Wire T ension Wheel 4 Drive Roll Install correct drive roll for wire size and type. 5 Drive Roll T ension Assembly T urn nut one click [...]

  • Page 12

    OM-188 414 Page 8 2-8. Selecting a Location and Connecting Input Power Have only qualified persons make this installation. 1 Rating Label Supply correct input power . ST-801 721 18 in (457 mm) for airflow GND/PE Connect First L1 L2 GND/PE 1 I 0 S 2-9. Installing Work Clamp 1 Wire Feeder Connection 2 W ork Connect 3 Negative Power Source T erminal 4[...]

  • Page 13

    OM-188 414 Page 9 SECTION 3 – OPERA TION 3-1. Controls 1 Handle 2 Wire Speed Control 3 Pilot Light 4 Spot T imer 5 Optional Amperage and V olt- meter 6 Power Switch 7 Thermal Overload Pilot Light 8 10 Position V oltage Control 9 T orch Connector 1 2 3 4 5 6 7 8 9[...]

  • Page 14

    OM-188 414 Page 10 SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace un readable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. during heavy service clean monthly . OR 4-2. Circuit Breaker CB1 1 Circuit B[...]

  • Page 15

    OM-188 414 Page 1 1 4-4. T roubleshooting T rouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-8). Replace building line fuse or reset circuit breaker if open (see Section 2-8). Reset circuit breaker CB1 (see Section 4-2). Secure gun trigger connections. Check and replace Power switch if necessary [...]

  • Page 16

    OM-188 414 Page 12 SECTION 5 – ELECTRICAL DIAGRAM L N 5.1 INTEGRA 201 cod.956.142.275 5.2 INTEGRA 241 cod.956.142.21 1 L N 10 0 10 0 JACK FEM. cod.956.142.21 1 BLACK NERO ROSSO RED[...]

  • Page 17

    OM-188 414 Page 13 SECTION 6 – P ARTS LIST 6.1 Common Parts Assembly 14 4 6 1 2 7 10 4 6 17 15 16 12 9 8 18 11 13 3 Item Dia Ref. Code Qty . Dwg Item Dia Ref. Code Qty . Dwg 1 000151 187 PV .0.0.18 1 2 1 16122284 UV .0.0.14 1 3 156087017 2 4 156009067 2 6 056054064 VS.0.0.13 2 7 1 16005165 DZ.0.0.25 1 8 150005001 1 9 15601 1002 2 10 1 16005316 UV[...]

  • Page 18

    OM-188 414 Page 14 6.2 Main Assembly 46 3 41 45 43 44 1 12 8 6 4 7 10 9 11 47 13 14 16 15 27 17 26 21 18 19 20 23 24 22 36 38 37 40 39 35 29 33 28 34 30 31 32 25 23 22 42 2 48 5 49 Item Dia Ref. Code Qty . Dwg 201 241 Item Dia Ref. Code Qty . Dwg 201 241 1 056052033 MD.4.0.1 1 1 2 156019694 FZ.0.9.1 3 3 3 156019672 MD.4.0.6 1 1 4 OPTIONAL 156053040[...]

  • Page 19

    Effective January 1, 2000 This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED W ARRANTY – Subject to the terms and conditions below , Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment s[...]

  • Page 20

    PRINTED IN USA  2000 Miller Electric Mfg. Co. 1/00 Miller Elect ric Mfg. Co. An I l li noi s T ool W orks Company 1635 W est Spencer Street Applet on, W I 5 4914 USA International He adquarters – USA Phone: 414-735-4505 USA & C anada F AX : 9 20-735-4134 Int ernational F AX: 920-735-4125 European Headquarters – United K ingdom Phone: 44 [...]