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Miller Electric S-22P12 manual

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Table of contents for the manual

  • Page 1

    S-22P12 Ultra-Lite Visit our website at www.MillerWelds.com Processes OM-181 931F November 2001 Description MIG (GMA W) W elding Flux Cored (FCA W) W elding Wire Feeder[...]

  • 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 catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • 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 . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 4

    dec_con1 1/96 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W . Spencer Street Appleton, WI 54914 USA Declares that the product: S-22P12 Ultra-Lite conforms t[...]

  • Page 5

    OM-181 931 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-181 931 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-181 931 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-181 931 Page 4 1-5. EMF Information Considerations About W elding And The Ef fects 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 ye[...]

  • Page 9

    OM-181 931 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulie[...]

  • Page 10

    OM-181 931 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dan[...]

  • Page 11

    OM-181 931 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharg[...]

  • Page 12

    OM-181 931 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, W ashington, D.C. 20402. Recommended Safe Practice fo[...]

  • Page 13

    OM-181 931 Page 9 SECTION 2 – DEFINITIONS 2-1. W arning Label 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 W arning! W atch Out! There are possible hazards as shown by the symbols. Drive rolls can injure fingers Welding wire and drive parts are at welding voltage during operation – keep hands and metal object[...]

  • Page 14

    OM-181 931 Page 10 2-2. Manufacturer ’ s Rating Label For CE Products ST-178 794-A For label location see Section 3-7. S/N: 24 7 Hz 50/60 IP 23 V 100 A 500 X 100 % MILLER ELECTRIC MFG. CO., APPLETON, WI USA V U 1 = A I 1 = 1 U 2 = I 2 = 2-3. Symbols And Definitions Some symbols are found only on CE products. NOTE Output Alternating Current A Ampe[...]

  • Page 15

    OM-181 931 Page 1 1 3-2. Equipment Connection Diagram ST-155 765-A 1 Constant V oltage (CV) W elding Power Source Supplying 24 V AC T o Feeder Use optional PSA-2 adapter for power sources having only 1 15 V AC supply. 2 Negative ( – ) W eld Cable 3 Positive (+) Weld Cable 4 W orkpiece 5 Interconnecting Cord (Customer Supplied) 6 14-Pin Plug And C[...]

  • Page 16

    OM-181 931 Page 12 3-4. Connecting Shielding Gas And 14-Pin Plug Ref. ST-801 155-A / Ref. ST -801 131 1 Gas Hose With 5/8-18 Right-hand Thread Fittings (Customer Supplied) 2 Shielding Gas Cylinder 3 V alve 4 Flowmeter Close valve on cylinder when fin- ished welding. 5 14-Pin Plug T ools Needed: 5/8 in 1 2 3 4 5 3-5. 14-Pin Plug Information Pin* Pin[...]

  • Page 17

    OM-181 931 Page 13 3-7. Connecting W eld Cable And Installing Drive Rolls ST-801 128-B / ST -162 079-A / Ref. S-180 967 1 Weld Cable From W elding Power Source Route weld cable from power source through rear panel and con- nect to terminal on drive assembly . Install and secure wire guide. Install drive rolls and turn drive roll nut one click. Only[...]

  • Page 18

    OM-181 931 Page 14 3-8. Installing And Threading Welding Wire ST-156 377-B / Ref. ST -159 048-A / S-0627-A Install wire spool. Adjust tension screw so wire is taut when wire feed stops. Lay gun cable out straight. Open pressure assembly , hold wire tightly , and cut of f end. Push wire through guides i n t o g u n . Close and tighten pressure assem[...]

  • Page 19

    OM-181 931 Page 15 SECTION 4 – OPERA TION 4-1. Controls ST-139 026-B 1 Wire Speed Meter (Optional) 2 V oltage Meter (Optional) 3 Power Control Switch 4 Jog/Purge Switch Push up to momentarily feed welding wire at speed set on Wire Speed control without energizing welding circuit or shielding gas valve. Push down to momentarily ener- gize gas valv[...]

  • Page 20

    OM-181 931 Page 16 5-2. Overload Protection Ref. 800 586-B / Ref. 801 128-B Y T urn Off wire feeder and welding power source. Stop engine on welding generator . 1 Circuit Breaker CB1 2 Fuse F1 CB1 and F1 protect wire feeder from overload. Correct problem and reset CB1 or replace F1. Close and latch door . 1 2 5-3. T roubleshooting T able T rouble R[...]

  • Page 21

    OM-181 931 Page 17 SECTION 6 – ELECTRICAL DIAGRAM 196 477-B Figure 6-1. Circuit Diagram For Wire Feeder With Options[...]

  • Page 22

    OM-181 931 Page 18 SECTION 7 – P ARTS LIST Figure 7-1. Main Assembly See T able 7-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 130 431-H[...]

  • Page 23

    OM-181 931 Page 19 Description Quantity Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly 1 058 427 RING, retaining spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 601 965 SCREW , cap stl hexhd .375-16 x 1.000 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 24

    OM-181 931 Page 20 Description Quantity Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly (Continued) 54 166 072 SP ACER, gear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 172 075 CARRIER, drive roll w/components 24 pitch 1 . . . . . . . . . . . .[...]

  • Page 25

    OM-181 931 Page 21 T able 7-1. Drive Roll And Wire Guide Kits 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 hard shelled cored [...]

  • Page 26

    OM-181 931 Page 22 Notes[...]

  • Page 27

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 10/01 Y o ur 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 expertise[...]

  • Page 28

    PRINTED IN USA  2001 Miller Electric Mfg. Co. 1/01 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 W est S pencer Street Applet on, W I 5 4914 USA International He adquarters – US A USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F AX : 920-735-4134 Int ernational F A X: 920-735-4125 European Headqua rters – Uni[...]