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Miller Electric OM-229 038D manual

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Table of contents for the manual

  • Page 1

    Migmatic 221/253 Processes Description MIG (GMA W) W elding Flux Cored (FCA W ) W elding Arc Welding Power Source Wire Feeder OM-229 038D 2007−04 Effective with serial number 226 214 R[...]

  • 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 W elding Hazards 1 . . . . . . . [...]

  • Page 4

    dec_stat_Milan_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: ITW Welding Products Italy S.r .l. Mr . Danilo Fedolfi, Via Privata Iseo 6/E Managing Director 20098 San Giuliano ITW Welding Products Italy[...]

  • Page 5

    OM-229 038 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[...]

  • Page 6

    OM-229 038 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 an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching [...]

  • Page 7

    OM-229 038 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-229 038 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[...]

  • Page 9

    OM-229 038 Page 5 SECTION 2 − DEFINITIONS W arning! W atch Out! There are possible hazards as shown by the symbols. 1 Electric shock can kill. 1.1 W ear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric shock by insulating yourself from work and ground. 1.3 Disconne[...]

  • Page 10

    OM-229 038 Page 6 W arning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Read the Owner ’ s Manual before working on this machine. 1 Consult rating label for input power requirements, and check power available at the job site − they [...]

  • Page 11

    OM-229 038 Page 7 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Electrical shock from wiring can kill. 3 Read Owner ’ s Manual before working on this machine 4 W ear approved safety glasses 5 Electrode Positive (Straight Polarity) 6 Electrode Negative (reverse Poalrity) 1 2 4 3 5 6 2-1. WEEE Label Do not discard thi[...]

  • Page 12

    OM-229 038 Page 8 SECTION 3 − INST ALLA TION 3-1. Specifications Rated Output Max. Rated Input Amperage at Rated Output Rated Output Max. Open Circuit Rated Input Amperage at Rated Output Dimension W eight Model 100% 60% 20% Open Circuit V oltage 220/230 V AC 50Hz Dimension (mm) W eight (kg) 221 90 A 18.5 V 11 6 A 20.0 V 210 A 24.0 V 41 32 A 3 A*[...]

  • Page 13

    OM-229 038 Page 9 3-3. V olt-Ampere Curves Th e volt-ampere curves show the normal minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. Model 253 MIN MAX Model 221 3-4. Installing Gas Supply Ref. ST-148 265-B / Ref. ST -149 827-B / Ref. ST-158 697-A 2 CO 2 [...]

  • Page 14

    OM-229 038 Page 10 3-5. Installing Wire Spool and Adjusting Hub T ension 072573-B When a slight force is needed to turn spool, tension is set. 24 mm (15/16 in) Use compression spring with 200 mm (8 in) spools. T ools Needed: 3-6. Positoning Jumper Links (230/400V 3-Phase Models) 230 V 400 V[...]

  • Page 15

    OM-229 038 Page 1 1 3-7. Electrical Service Guide Migmatic Model 221 253 Input V oltage 220/230 230 400 Input Amperes at Rated Output 26 23 13 Max Recommended Standard Fuse or Circuit Breaker Rating in Amperes 26 23 13 ** Input Conductor Size in mm 2 4 4 4 ** Grounding Conductor Size in mm 2 4 4 4 ** Power cord supplied with the unit is sized for 2[...]

  • Page 16

    OM-229 038 Page 12 B. 3-Phase 803 766-A Y Installation must meet all National an d Local Codes − have only quali- fied persons make this installation. Y Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Y Always connect green or green/ yellow conductor to supply grounding term i n a l f i r s t , a n d neve[...]

  • Page 17

    OM-229 038 Page 13 3-9. Installing Drive Rolls and Wire Guide 1 Securing Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close to drive rolls as possible without touching. Tigh ten screw . 3 Anti-W ear Guide Install guide as shown. 4 Drive Roll The drive roll consists of two dif fer- ent sized grooves. The stamped markings on the end surface o[...]

  • Page 18

    OM-229 038 Page 14 3-10. Threading W elding Wire and Adjusting Pressure Roll T ension 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight. 4 7 5 6 2 1 T ools Needed: 150 mm . Hold wire tightly to keep it from unraveling. WOOD Open pressure assembly[...]

  • Page 19

    OM-229 038 Page 15 1 Consumable Storage Compartment Press latch down to release and open door . Provides storage space for gas nozzles, contact tips, gas dif fusers. 3-1 1. Using Gun/Cable Holder 1 3-12. Setting Gun Polarity for Wire T ype (Optional) 1 Electrode Positive (DCEP) For solid steel, stainless steel, alu- minum, or flux core with gas, wi[...]

  • Page 20

    OM-229 038 Page 16 SECTION 4 − OPERA TION 4-1. Controls for Migmatic 221/253 1 Power Switch 2 V oltage Control T urn control clockwise to increase voltage. 3 High T emperature Shutdown Light (Orange LED) 4 Digital Display* V olts/Amps/Wire Feed Speed with last value hold function. T rigger mode (2T/4T) is shown a t power on for 3 seconds and when[...]

  • Page 21

    OM-229 038 Page 17 SECTION 5 − MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals 6 Months Blow out or vacuum inside. OR Remove drive roll and carrie[...]

  • Page 22

    OM-229 038 Page 18 5-4. T roubleshooting T rouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 3-8). Replace building line fuse or reset circuit breaker if open. Reset circuit breaker CB1 (see Section 5-2). Secure gun trigger connections. Check continuity of power switch S1 and replace if necessary . [...]

  • Page 23

    OM-229 038 Page 19 Notes[...]

  • Page 24

    OM-229 038 Page 20 SECTION 6 − ELECTRICAL DIAGRAMS September 21, 2006 W ARNING Electric Shock Hazard S Do not touch live electrical parts. S Disconnect input power or stop engine before servicing. S Do not operate with covers removed. S Have only qualified persons install, use, or service this unit. Figure 6-1. Circuit Diagram for Migmatic 221[...]

  • Page 25

    OM-229 038 Page 21 September 21, 2006 W ARNING Electric Shock Hazard S Do not touch live electrical parts. S Disconnect input power or stop engine before servicing. S Do not operate with covers removed. S Have only qualified persons install, use, or service this unit. Figure 6-2. Circuit Diagram for Migmatic 253 (400 V AC)[...]

  • Page 26

    OM-229 038 Page 22 SECTION 7 − P ARTS LIST Figure 7-1. W rapper Assembly , All Models[...]

  • Page 27

    OM-229 038 Page 23 Description Part No. Item No. Figure 7-1. W rapper Assembly , All Models Quanti ty 1 156034005 Catch, side panel 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 156122062 Side Panel, hinged 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 28

    OM-229 038 Page 24 Figure 7-2. Main Assembly for Migmatic 221[...]

  • Page 29

    OM-229 038 Page 25 Description Part No. Dia. Mkgs. Item No. Figure 7-2. Main Assembly for Migmatic 221 Quanti ty 1 956142538 Label 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 000186436 Washer , plastic 1 . . . . . . . . . . . . . . [...]

  • Page 30

    OM-229 038 Page 26 Figure 7-3. Main Assembly for Migmatic 253[...]

  • Page 31

    OM-229 038 Page 27 Description Part No. Dia. Mkgs. Item No. Figure 7-3. Main Assembly for Migmatic 253 Quantity 230V 400V 1 956142538 Label 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 000186436 Washer , plastic 1 1 . . . . . . . . .[...]

  • Page 32

    OM-229 038 Page 28 T able 7-1. Drive Roll And Wire Guide Kits (2 Roll Models) Base selection of drive rolls upon the following recommended usages: 1. V -Grooved rolls for hard wire. 2. U-Grooved rolls for soft and soft shelled cored wires. 3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4. V -Knurled rolls for har[...]

  • Page 33

    Notes[...]

  • Page 34

    Notes[...]

  • Page 35

    Effective January 1, 2007 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 , ITW W elding Products Italy S.r .l., warrants to its original retail purchaser that new Miller equipment sold after [...]

  • Page 36

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 1/07 I TW W elding Products Italy S.r . l. Via Privata Iseo, 6/E 20098 San Giuliano Milanese, Italy Phone: 39 (0) 2982901 Fax: 39 (0) 298290-203 email: miller@itw−welding.it Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address Co[...]