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Miller Electric Migmatic 221, Owner'S Manual

The Miller Electric Migmatic 221 is a versatile welding machine designed for both personal and professional use. With its advanced features and user-friendly interface, this product ensures seamless welding experiences. To get the most out of your welding machine, make sure to download the free Owner's Manual from manualshive.com for detailed instructions and tips.

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OM-229 038 Page 25

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 7-2.  Main Assembly for Migmatic 221

Quantity

1

956142538

Label

1

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2

000186436

Washer, plastic

1

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3

000186435

Hub

1

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4

156009075

Washer, flat

1

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5

156032064

Spring

1

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6

156009079

Washer, flat

1

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7

156018033

Nut

1

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8

156032128

Spring

1

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9

000058427

Ring

1

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10

000207076

Knob, pointer

2

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11

656043043

Grommet, blank plug

2

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12

000193144

Plastic, change polarity

1

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13

356031003

Buss Terminal, polarity change

2

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14

028033029

Wire Drive System, 2 roll d.37

1

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15

156090018

Wire Guide, outlet

1

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16

028066257

Connector, quick female

1

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17

V56005028

Plastic, Euro

1

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18

PC2

057095015

Circuit Board, digital volt / amp / wire speed display

1

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19

RC1

056059274

Potentiometer, 1k ohms

1

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20

PL2

056072075

Lamp, pilot 24v orange

1

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21

PL1

056072076

Lamp, pilot 24v white

1

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22

000207075

Knob, pointer

1

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23

056020069

Knob, pointer d.7

1

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24

RC1

028066258

Receptacle, Spoolmate jack plug

1

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25

056076152

Coupler, female 50mmq

1

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26

116118175

Panel, front

1

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27

000155436

Label, ground

1

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28

156006040

Base

1

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29

FM1

057035018

Motor, fan

1

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30

116116176

Panel, rear

1

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31

V56018092

Nut, plastic

1

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32

GSV

056061042

Solenoid, gas valve 24 vac

1

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33

956142504

Label, rear

1

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34

V56091091

Clamp

1

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35

057014199

Line Cable

1

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36

F1

*056092039

Fuse, 10a 500v

1

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37

056092094

Fuseholder

1

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38

T2

058021141

Transformer, auxillary

1

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39

156005108

Support, spool

1

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40

W

057079032

Contactor, 7.5 kw−230v

1

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41

PC1

057084126

Circuit Board, control

1

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42

CB1

056067188

Circuit Breaker

1

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43

R2

056059275

Potentiometer, 10k

1

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44

R3

056059277

Potentiometer, 10k+sw

1

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45

C1

056082098

Capacitor, 15,000 mf

4

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46

SR1

056050151

Rectifier, silicon

1

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47

TP1

056159008

Thermostat 115

°

1

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48

056059257

Shunt, 300 mA

1

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49

117060018

Plate, baffle

1

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50

V56033124

Grommet, cable entry

1

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51

000178937

Label, drive

1

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52

116014026

Support, front

1

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53

S2

056067189

Switch, 25a 10 pos

1

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54

S1

056067251

Switch, primary power on/off

1

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55

T1

028021464

Transformer, 3ph 250a 230/400v

1

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56

Z1

058028019

Stabilizer, 210a

1

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57

027061026

Hose, gas mt 1.7 5*11

1

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58

000176106

Label, fan

1

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*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Summary of Contents for Migmatic 221

Page 1: ...Migmatic 221 253 Processes Description MIG GMAW Welding Flux Cored FCAW Welding Arc Welding Power Source Wire Feeder OM 229 038D 2007 04 Effective with serial number 226 214 R ...

Page 2: ...ducts Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The par...

Page 3: ...ting Hub Tension 10 3 6 Positoning Jumper Links 230 400V 3 Phase Models 10 3 7 Electrical Service Guide 11 3 8 Selecting a Location and Connecting Input Power 1 Phase and 3 Phase 11 3 9 Installing Drive Rolls and Wire Guide 13 3 10 Threading Welding Wire and Adjusting Pressure Roll Tension 14 3 11 Using Gun Cable Holder 15 3 12 Setting Gun Polarity for Wire Type Optional 15 SECTION 4 OPERATION 16 ...

Page 4: ...39 02 98290 1 Fax 39 02 98290203 European Contact Signature Declares that this product Migmatic 221 253 conforms to the following Directives and Standards Directives Electromagnetic Compatibility Directives 89 336 EEC Low Voltage 73 23 EEC Machinery Directives 89 392 EEC And their amendments 91 368 EEC 92 31 EEC 93 44 EEC 93 68 EEC 98 37 EC Standards Electromagnetic compatibility EMC EN50199 Augus...

Page 5: ...10 147 see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach prop...

Page 6: ...ombustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag D Wear approved safety glasses with side shield...

Page 7: ...es computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion D If notified by the FCC about interference stop using the equipmentat once D Have the installation regularly checked and maintaine...

Page 8: ...A Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 6 EMF Information Considerations About Welding And The...

Page 9: ...parks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with corr...

Page 10: ...e 4 Having a loop of extra length connect grounding conductor first 5 Connect line input conductors as shown on inside label double check all connections jumper link positions and input voltage before applying power 1 Warning Watch Out There are possible hazards as shown by the symbols 2 Moving parts such as fans can cut fingers and hands and cause injury Keep away from moving parts S 176 106 1 2 ...

Page 11: ... 4 Wear 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 this product with general waste Reuse or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collec tion facility Contact your local recycling office or your local distributor for further information ...

Page 12: ...60 35 Open Circuit Voltage 230 V 400 V Dimension mm Weight kg 253 145 A 21 0 V 190 A 23 0 V 250 A 26 5 V 38 23 A 3 A 13 A 1 38 A 480 x 800 x 1050 85 103 Net Wire feed speed range 1 3 mpm to 20 mpm While idling 3 2 Duty Cycle And Overheating 6 Minutes Welding 4 Minutes Resting Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats thermostat s...

Page 13: ...talling Gas Supply Ref ST 148 265 B Ref ST 149 827 B Ref ST 158 697 A 2 CO2 Gas 1 Argon Gas OR 3 Chain gas cylinder to running gear wall or other stationary support so cylinder cannot fall and break off valve 1 Regulator FlowGauge Install so face is vertical 2 Gas Hose Connection 3 Flow Adjust Typical flow rate is 0 9 liters per minute Check wire manufactur er s recommended flow rate This flow gau...

Page 14: ... Spool and Adjusting Hub Tension 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 Tools Needed 3 6 Positoning Jumper Links 230 400V 3 Phase Models 230 V 400 V ...

Page 15: ...agout in put power before connecting input conductors from unit Y Always connect green or green yellow conductor to supply grounding terminal first and never to a line terminal 1 Black And White Input Conductor L1 And L2 2 Green Or Green Yellow Grounding Conductor 3 Input Power Cord 4 Disconnect Device switch shown in the OFF position 5 Disconnect Device Grounding Terminal 6 Disconnect Device Line...

Page 16: ...in the OFF position 3 Green Or Green Yellow Grounding Conductor 4 Disconnect Device Grounding Terminal 5 Input Conductors L1 L2 And L3 6 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 L2 and L3 to disconnect device line terminals 7 Over Current Protection Select type and size of over curre...

Page 17: ...ew 3 Anti Wear Guide Install guide as shown 4 Drive Roll The drive roll consists of two differ ent sized grooves The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll The groove closest to the motor shaft is the proper groove to thread Turn nut one click to secure drive roll Tools Needed 5 64 in 7 16 in 2 1 3 4 221 253 7 ...

Page 18: ...assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn On Press gun trigger until wire comes out of gun Reinstall contact tip and nozzle Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close and latch door Ref 802 064 D S 06...

Page 19: ...les contact tips gas diffusers 3 11 Using Gun Cable Holder 1 3 12 Setting Gun Polarity for Wire Type Optional 1 Electrode Positive DCEP For solid steel stainless steel alu minum or flux core with gas wires GMAW 2 Electrode Negative DCEN For gasless flux core wires FCAW wire drive assembly be comes negative 1 2 221 253 4 221 253 5 ...

Page 20: ...to increase wire feed speed This control also controls optional spool gun if con nected 7 Digital Display Function Button 8 MIG Torch Connection Connection for Euro style MIG gun or optional spoolmate gun 9 Spool Gun Connection Jack Plug Receptacle Insert jack plug of Spoolmate gun to enable torch motor 10 Work Lead Connection Optional 1 2 3 4 5 6 7 8 9 10 221 253 2 4 2 Burnback and Spot Weld Time...

Page 21: ...Circuit Breaker CB1 CB1 protects the unit from over loading of drive motor M1 If CB1 opens wire feeding stops 2 Welding Gun Check gun liner for blockage or kinks 3 Wire Drive Assembly Check for jammed wire binding drive gear or misaligned drive rolls Allow cooling period and reset breaker Close door 2 221 253 4 1 3 5 3 Unit Overload Thermal switches TP1 in XFMR and TP2 in SR1 protect the unit from...

Page 22: ...and check connections Replace Z1 if necessary Check main transformer T1 for signs of winding failure Check continuity across windings and check con nections Check secondary voltages Replace T1 if necessary Check voltage switch s Replace if necessary Low weld output Connect unit to proper input voltage or check for low line voltage see Section 3 6 Check input voltage jumper links and correct positi...

Page 23: ...OM 229 038 Page 19 Notes ...

Page 24: ... WARNING 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: ...hock 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 VAC ...

Page 26: ...OM 229 038 Page 22 SECTION 7 PARTS LIST Figure 7 1 Wrapper Assembly All Models ...

Page 27: ... 1 12 000207291 Label primary power connections 1 13 156121026 Cover 1 14 056054068 Wheel Caster front 80 O D 2 15 000213051 Bezel lower 1 16 156002045 Handle 1 17 000213053 Plastic upper 1 18 000207233 Label general precautionary 1 19 156122063 Plate expanded 1 20 000208044 Screw torx self tapping 10 21 316029709 Nameplate upper Migmatic 253 1 21 316029714 Nameplate upper Migmatic 221 1 22 956142...

Page 28: ...OM 229 038 Page 24 Figure 7 2 Main Assembly for Migmatic 221 ...

Page 29: ...M1 057035018 Motor fan 1 30 116116176 Panel rear 1 31 V56018092 Nut plastic 1 32 GSV 056061042 Solenoid gas valve 24 vac 1 33 956142504 Label rear 1 34 V56091091 Clamp 1 35 057014199 Line Cable 1 36 F1 056092039 Fuse 10a 500v 1 37 056092094 Fuseholder 1 38 T2 058021141 Transformer auxillary 1 39 156005108 Support spool 1 40 W 057079032 Contactor 7 5 kw 230v 1 41 PC1 057084126 Circuit Board control...

Page 30: ...OM 229 038 Page 26 Figure 7 3 Main Assembly for Migmatic 253 ...

Page 31: ...8 Motor fan 1 1 30 116116176 Panel rear 1 1 31 V56018092 Nut plastic 1 1 32 GSV 056061042 Solenoid gas valve 24 vac 1 1 33 956142504 Label rear 1 1 34 V56091091 Clamp 1 1 35 057014197 Line Cable 1 1 36 756069012 Bracket change tension 1 37 556070011 Link primary power terminal 230 460 3 38 F1 056092039 Fuse 10a 500v 1 1 39 056092094 Fuseholder 1 1 40 T2 058021141 Transformer auxillary 1 1 41 15600...

Page 32: ...ard shelled cored wires 5 Drive roll types may be mixed to suit particular requirements example V Knurled roll in combination with U Grooved NOTE Wire Diameter Drive Roll Wire Guide Metric Fraction Decimal Part No Type Inlet 0 6 0 8 mm 0 023 0 030 in 0 023 0 030 in 156053100 V 156090018 0 8 1 mm 0 030 0 035 in 0 030 0 035 in 156053101 V 156090018 1 1 2 mm 0 035 0 045 in 0 035 0 045 in 156053102 V ...

Page 33: ...Notes ...

Page 34: ...Notes ...

Page 35: ...Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment tha...

Page 36: ...ostal Code Please complete and retain with your personal records Owner s Record Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Service and Repair Replacement Parts Owner s Manuals Contact the Delivering Carrier to For Service File a claim for loss or damage during shipment For assistance in...

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