Miller Electric MPi 220P Owner'S Manual Download Page 54

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OM-253 918 Page 48

SECTION 8

−

MIG WELDING (GMAW) GUIDELINES

mig1 2009

−

Wire Feeder/

Power Source

Workpiece

Gun

Regulator/

Flowmeter

Gas

Shielding Gas

Work Clamp

8-1. Typical MIG Process Connections

Weld current can damage

electronic parts in vehicles.

Disconnect both battery

cables before welding on a

vehicle. Place work clamp as

close to the weld as possible.

Ref. 801 909-A

Summary of Contents for MPi 220P

Page 1: ...Processes Description Multiprocess Welding OM 253 918B 2012 02 Visit our website at www MillerWelds com File Multiprocess MPi 220P CE...

Page 2: ...ucts 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...

Page 3: ...And Wire Inlet Guide 17 4 9 Aligning Drive Rolls and Wire Guide 18 4 10 Electrical Service Guide 19 4 11 Connecting 230 VAC Single Phase Input Power 20 4 12 Threading Welding Wire And Adjusting Press...

Page 4: ...8 11 Troubleshooting Lack Of Penetration 54 8 12 Troubleshooting Incomplete Fusion 54 8 13 Troubleshooting Burn Through 54 8 14 Troubleshooting Waviness Of Bead 55 8 15 Troubleshooting Distortion 55...

Page 5: ...Standards IEC 60974 1 Arc Welding Equipment Welding Power Sources edition 3 2005 07 IEC 60974 5 Arc Welding Equipment Wire Feeders edition 2 2007 11 IEC 60974 10 Arc Welding Equipment Electromagnetic...

Page 6: ......

Page 7: ...ds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following eq...

Page 8: ...ums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoli...

Page 9: ...NG PARTS can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards...

Page 10: ...ntion During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Healt...

Page 11: ...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 eye...

Page 12: ...ch 2 Read Owner s Manual and inside labels for connection points and procedures 3 Move jumper links as shown on inside label to match voltage at job site 4 Having a loop of extra length connect ground...

Page 13: ...1 Electrode Positive Straight Polarity 2 Electrode Negative Reverse Polarity DCEP Electrode Positive DCEN Electrode Negative 956 142 877 A 1 2 2 1 WEEE Label Do not discard this product with general...

Page 14: ...ng GMAW U1 Primary Voltage I1max Rated Maximum Supply Current I1eff Maximum Effective Supply Current U2 Conventional Load Voltage I2 Rated Welding Current X Duty Cycle Percent U0 Rated No Load Voltage...

Page 15: ...20 of the permissible values 3 2 Information On Electromagnetic Compatibility EMC This Class A equipment is not intended for use in residential locations where the electrical power is provided by the...

Page 16: ...fteen minutes for unit to cool Reduce amperage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit or gun and void warranty 3 4 Duty Cycle And Overheating Overheating 0 15 A or V...

Page 17: ...of other settings fall between the curves shown A MIG 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 0 DC Amperes DC Volts 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 23...

Page 18: ...ded on back cover of this manual Operating Temperature Range 14 F 10 C to 104 F 40 C Ratingt were developed at an ambient temperature of 20 C to 25 C Do not move or operate unit where it could tip 1 L...

Page 19: ...blows dust and dirt from valve Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect su...

Page 20: ...ative Positive Ref 956142881_ A 100 20 4 20 4 20 4 30 3 35 2 50 1 60 1 0 60 1 0 150 30 3 30 3 35 2 50 1 60 1 0 70 2 0 95 3 0 95 3 0 200 30 3 35 2 50 1 60 1 0 70 2 0 95 3 0 120 4 0 120 4 0 250 35 2 50...

Page 21: ...Polarity 956142881_2 A 1 Lead Connections For Direct Current Electrode Positive DCEP 2 Lead Connections For Direct Current Electrode Negative DCEN Always read and follow wire manufacturer s recommend...

Page 22: ...ng Wire Spool And Adjusting Hub Tension 956142881_20 B 1 Wire Spool 5 kg 2 Handwheel Allows adjustment of hub tension Turn handwheel clockwise to in crease tension 3 Spool Holder Cap Tighten to secure...

Page 23: ...t touching Tighten setscrew 3 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...

Page 24: ...n 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear Insert screwdriver and turn screw in or out until drive roll groove lines up with wire guide Close pressure roll assem...

Page 25: ...Meters Feet 29 95 Min Grounding Conductor Size In AWG 4 6 10 Reference 2011 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit break...

Page 26: ...site 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Disconnect Device Grounding Terminal 4 Disconnect Device Line Terminals 5 Black And White Input Conductor L1 And L2 6 Gre...

Page 27: ...embly 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 Press gun trigger unt...

Page 28: ...rocess 5 Process Selector Switch Use switch to select process TIG STICK or MIG 6 Program Sequencer Switch Use switch to select programs and scroll through sequencer paramet ers while in MIG mode see S...

Page 29: ...lect or P1 push button to select Stick welding Corresponding symbol is displayed While in Stick mode the output is set to off Output is turned on off by pressing and releasing Sequencer set up P2 push...

Page 30: ...utput terminal Turn power on Allow time for unit complete its start up cycle Press and release Process select or switch to select TIG welding Corresponding symbol is dis played Use amperage adjustment...

Page 31: ...control to select amount of time that it takes to slope up down from weld amperage to final amperage To disable set to 0 When this item is selected use the Wire Feed Speed adjustment knob or Sequen ce...

Page 32: ...utton 2 Sequencer Set Up P2 Push Button 3 Sequencer Adjustment Operator Point Setting P3 Push Buttons See Section 5 16 4 Welding Voltage Adjustment Knob Use knob to select desired welding voltage Rota...

Page 33: ...ed adjust ment knob or Sequencer adjust ment P3 push buttons to change the value see Section 5 7 6 Slope Time Use control to select amount of time that it takes to slope up down from initial amperage...

Page 34: ...rs per second providedno other changes are made and increase the arc on time The increased arc on time makes the welding puddle more fluid 9 Postflow Time Use control to set length of time gas flows a...

Page 35: ...e P3 push but tons or Wire Feed Speed WFS ad justment knob 5 2T Trigger Mode When trigger is pressed welding starts When trigger is released welding stops 6 4T Trigger Mode When trigger is pressed wel...

Page 36: ...kwise to increase the thickness value 5 Arc Length Control Knob Use knob to select desired arc length value It is the distance from end of wire electrode to the workpiece Rotate knob clockwise to incr...

Page 37: ...and release process selection P1 push button Desired parameters will be stored 5 Trigger Mode 2T 4T Use arc length control knob or se quencer adjustment P3 push but tons to change value see Section 5...

Page 38: ...ct ance is for stainless steel and spray arc applications In short circuit GMAW welding an increase in inductance will decrease the number of short circuit transfers per second providedno other change...

Page 39: ...f shieldingwire no shielding gas process 1 Process Selection P1 Push Button 2 Sequencer Set Up P2 Push Button 3 Sequencer Adjustment Operator Point Setting P3 Push Buttons See Section 5 16 4 Workpiece...

Page 40: ...ces vary little spatter because the wire does not touch the weld puddle Ap plications best suited for pulsed MIG are those currently using the short circuit transfer method for welding steel 14 gauge...

Page 41: ...eters will be stored 5 Trigger Mode 2T 4T Use arc length control knob or se quencer adjustment P3 push but tons to change value see Section 5 7 6 Slope Time Use Arc Length control knob to se lect amou...

Page 42: ...e Default 120 min 100 max 150 3 Welding Current Percentage Percent reduction of welding cur rent during the crater fill process When this item is selected use the Arc Length control knob or Sequen cer...

Page 43: ...ension see Section 4 12 Without starting a weld press and hold torch trigger for three seconds to load welding wire After pressing and holding the torch trigger gas valve and in put power contactor ar...

Page 44: ...sic set up menu will be displayed Press and hold P2 until OK is displayed by re setting parameters Factory de faults are now restored H P2 Press And Hold 1 5 15 Loading A Program Ref 956142887 A To lo...

Page 45: ...s will be stored Press and hold Sequencer P2 push button for about 10 seconds to save parameters Saving OK will be dis played on the digital meter Press and release process selection P1 push button to...

Page 46: ...under normal operating conditions 1 Power Switch Use power switch to turn unit on When Miller appears on the display press and release sequencer set up P2 push button Unit is at de fault setting of H...

Page 47: ...set to MPM 4 Voltage Reduction Device VRD Settings Press and release P2 push button to select desired parameter Use P3 push buttons to change value This value is either OFF or ON Default is set to ON...

Page 48: ...haft Clean Drive Rolls 6 2 Welding Gun And Wire Drive Assembly 956142881_3 A 1 Welding Gun Check gun liner for blockage or kinks 2 Wire Drive Assembly Check for jammed wire binding drive gear or misal...

Page 49: ...imary and secondary power circuit of the unit Have Factory Authorized Service Agent check main transformer T1 for signs of winding failure Check continuity across windings and check for proper connect...

Page 50: ...trol is not connected C TIG GTAW Welding Trouble Remedy Wanderingarc hard starts poor welding characteristics spattering problems Use proper type and size of tungsten Use properly prepared tungsten Ch...

Page 51: ...OM 2253 918 Page 45 Notes...

Page 52: ...OM 253 918 Page 46 SECTION 7 ELECTRICAL DIAGRAMS Figure 7 1 Circuit Diagram For Welding Power Source...

Page 53: ...OM 2253 918 Page 47 956142882 B...

Page 54: ...er Source Workpiece Gun Regulator Flowmeter Gas Shielding Gas Work Clamp 8 1 Typical MIG Process Connections Weld current can damage electronic parts in vehicles Disconnect both battery cables before...

Page 55: ...arameters 035 in Recommendation Wire Speed Approx 1 8 or 0 125 in 0 001 in 1 ampere 0 125 in 125 A Wire Size Amperage Range 0 023 in 0 030 in 0 035 in Select Wire Size Wire Size 0 023 in 0 030 in 0 03...

Page 56: ...in 13 mm past end of nozzle and tip of wire is positioned correctly on seam 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm 5 Cradle...

Page 57: ...electrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage Slow FILLET WELD ELECTODE EXTENSIONS STICKOUT ELECTRODE EXTENSIONS STICKOUT GUN ANGLES AND WE...

Page 58: ...t Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 8 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slig...

Page 59: ...in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove s...

Page 60: ...welding power source 8 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actio...

Page 61: ...upport hand on solid surface or use two hands 8 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of th...

Page 62: ...f damaged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on...

Page 63: ...ecessary Wrong size gun liner or contact tip Match liner and contact tip to wire size and type Incorrect voltage setting for selected wire feed speed on welding power source Readjust welding parameter...

Page 64: ...is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode re quires less current than a large one Follow electrode manufactur er s instructions when setting weld amperage see Sectio...

Page 65: ...ALL ALL ALL FLAT HORIZ FILLET ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE...

Page 66: ...Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 9 6 Good Weld Bead Characteristics S 0052 B 1 Fine Spat...

Page 67: ...of base metal 9 8 Electrode Movement During Welding S 0054 A Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across g...

Page 68: ...5 mm 30 2 1 1 16 in 1 6 mm 3 4 9 10 Lap Joint S 0063 S 0064 1 Electrode 2 Single Layer Fillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fill...

Page 69: ...rm near weld bead Possible Causes Corrective Actions Amperage too high for electrode Decrease amperage or select larger electrode Arc length too long or voltage too high Reduce arc length or voltage I...

Page 70: ...se and or maintain steady travel speed Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input S...

Page 71: ...11 to 35 CFH cubic feet per hour Figures listed are a guide and are a composite of recommendations from American Welding Society AWS and electrode manufacturers 10 2 Preparing Tungsten Electrode For...

Page 72: ...nmentally safe way Wear proper face hand and body protection Keep flam mables away 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4...

Page 73: ...ch to front of pool Repeat process 75 75 Welding direction Form pool Tilt torch Add filler metal Move torch to front of pool Repeat process Remove rod Welding direction 15 11 3 Positioning Torch Tungs...

Page 74: ...OM 253 918 Page 68 SECTION 12 PARTS LIST Hardware is common and not available unless listed 956142881_17 B Figure 12 1 Main Assembly...

Page 75: ...ale 25MMQ 1 27 056076271 Receptacle 2P Gun Trigger 1 28 956142876 Nameplate Mpi 220P 1 29 156118081 Bezel Front 1 30 156118079 Panel Front 1 31 193919 Knob Pointer 2 32 356029244 Nameplate Mpi 220 Upp...

Page 76: ...OM 253 918 Page 70 956142881_18 A Hardware is common and not available unless listed See Drive Roll And Wire Guide Kits Figure 12 2 Wire Drive Assembly...

Page 77: ...156003036 Gear Upper Drive Roll Assembly d 17x32 5 2 25 156053112 Drive Roll Upper Pressure Arm Housing d 17x30 2 26 156019805 Bolt M5x25 Through Housing 2 27 756009061 Washer Insulator Drive Assembl...

Page 78: ...d 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 156053051 V 156090026 0 8 1 0 mm 0 030 0 035 in 0 030 0 035 in 156053109 V 1 0...

Page 79: ...ing Gear and Trailers Subarc Wire Drive Assemblies Water Coolant Systems USA Models Non Integrated Work Stations Weld Tables No Labor 5 6 Months Parts Batteries 6 90 Days Parts Accessory Kits Canvas C...

Page 80: ...ountry Zip Postal 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 S...

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