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TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

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1-1.

Symbol Usage

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1-2.

Arc Welding Hazards

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1-3.

Additional Symbols For Installation, Operation, And Maintenance

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1-4.

California Proposition 65 Warnings

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1-5.

Principal Safety Standards

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1-6.

EMF Information

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SECTION 2 − DEFINITIONS

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2-1.

Additional Safety Symbols And Definitions

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2-2.

Miscellaneous Symbols And Definitions

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SECTION 3 − SPECIFICATIONS

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3-1.

Serial Number And Rating Label Location

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3-2.

Specifications

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3-3.

Environmental Specifications

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3-4.

Duty Cycle And Overheating

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3-5.

Volt-Ampere Curves

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SECTION 4 − INSTALLATON

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4-1.

Selecting A Location

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4-2.

Installing Gas Supply

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4-3.

Installing Wire Spool And Adjusting Hub Tension

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4-4.

Positioning Jumper Links (230/400V 3-Phase Models)

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4-5.

Electrical Service Guide

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4-6.

Connecting Input Power (1-Phase and 3-Phase)

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4-7.

Installing Drive Rolls And Wire Guide

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4-8.

Threading Welding Wire And Adjusting Pressure Roll Tension

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SECTION 5 − OPERATION

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5-1.

Controls For MigMatic 220/250

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5-2.

Burnback And Spot Weld Timer Controls

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5-3.

Controls For MigMatic 220 DX / 250 DX

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5-4.

Burnback And Spot Weld Timer Controls

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5-5.

Welding Power Source Input Line Voltage Adjustment (DX Models Only)

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5-6.

Welding Power Source Setup Menu (DX Models Only)

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5-7.

Trigger Mode Selection (DX Models Only)

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5-8.

Spool Gun Mode (DX Models Only)

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5-9.

Welding Wire Diameter Selection For Synergic MIG (DX Models Only)

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5-10. Welding Wire Type Selection For Synergic MIG (DX Models Only)

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5-11. Gas Selection For Synergic MIG (DX Models Only)

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5-12. Selecting Manual MIG Welding (DX Models Only)

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5-13. Selecting Synergic MIG Welding (DX Models Only)

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SECTION 6 − MAINTENANCE &TROUBLESHOOTING

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6-1.

Routine Maintenance

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6-2.

Circuit Breaker CB1

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6-3.

Unit Overload

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6-4.

Troubleshooting

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SECTION 7 − ELECTRICAL DIAGRAMS

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SECTION 8 − PARTS LIST

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WARRANTY

Содержание MigMatic 220

Страница 1: ...NUAL Visit our website at www MillerWelds com Processes Description MIG GMAW Welding Flux Cored FCAW Welding Arc Welding Power Source Wire Feeder OM 246 691F 2015 06 MigMatic 220 250 Base DX R CE File...

Страница 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...

Страница 3: ...ase and 3 Phase 16 4 7 Installing Drive Rolls And Wire Guide 20 4 8 Threading Welding Wire And Adjusting Pressure Roll Tension 21 SECTION 5 OPERATION 22 5 1 Controls For MigMatic 220 250 22 5 2 Burnba...

Страница 4: ...MIGMATIC 250 DX 230 400VAC 029015525 Council Directives 2006 95 EC Low Voltage 2004 108 EC Electromagnetic Compatibility 2011 65 EU Restriction of the use of certain hazardous substances in electrica...

Страница 5: ...neeling 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 equipment in order presented 1 a semiautomaticDC...

Страница 6: ...ared 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 gasoline D Connect work cable to the work as clo...

Страница 7: ...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...

Страница 8: ...NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code...

Страница 9: ...rself from work and ground Safe3 2012 05 Disconnect input plug or power before working on machine Safe5 2012 05 Keep your head out of the fumes Safe6 2012 05 Use forced ventilation or local exhaust to...

Страница 10: ...wire and drive parts are at welding voltage during operation keep hands and metal objects away Safe33 2012 05 10 Falling unit can cause injury Do not move or operate unit where it could tip Safe53 201...

Страница 11: ...Current I1eff Maximum Effective Supply Current U2 Conventional Load Voltage I2 Rated Welding Current X Duty Cycle Percent U0 Rated No Load Voltage OCV IP Degree Of Protection Circuit Breaker Three Ph...

Страница 12: ...ation unless sheltered 10 to 40 C 14 to 104 F IP23S 2014 06 B Information On Electromagnetic Fields EMF This equipment shall not be used by the general public as the EMF limits for the general public...

Страница 13: ...elding NOTICE Exceeding duty cycle can damage unit and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes 35 Duty Cycle At 250 Amperes 100 Duty Cycle At 145 Amperes sduty1 5 95 DUTY CY...

Страница 14: ...Device Locate unit near correct input pow er supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 4 1 Selecting A Location...

Страница 15: ...o 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...

Страница 16: ...OM 246 691 Page 12 4 3 Installing Wire Spool And Adjusting Hub Tension Ref D2 Tools Needed Hub Assembly 15 Kg Wire Spool Assembly 5 Kg Wire Spool Assembly 1 Spacers Use only for 5Kg spool 1...

Страница 17: ...00 Volts 400 Volts 956142718_3 5 Disconnect and lockout tag out input power before instal ling or moving jumper links Check input voltage available at site 1 Jumper Link Label Check label only one is...

Страница 18: ...30 400 Input Amperes A At Rated Output 34 28 16 Max Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses 2 40 30 15 Normal Operating Fuses 3 50 40 25 Min Input Conductor Size In mm2 AWG 4 10...

Страница 19: ...OM 246 691 Page 15 Notes...

Страница 20: ...OM 246 691 Page 16 4 6 Connecting Input Power 1 Phase and 3 Phase A 1 Phase input4 2012 05 Ref D4 2 1 L1 L2 1 GND PE Earth Ground 6 5 3 4 7 Tools Needed...

Страница 21: ...witch 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 Green Or Green Yellow Grounding Conductor Connec...

Страница 22: ...OM 246 691 Page 18 B 3 Phase input2 2012 05 Ref D5 GND PE Earth Ground L1 2 1 L2 L3 3 3 4 5 6 7 Tools Needed...

Страница 23: ...isconnect Device switch shown 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...

Страница 24: ...hing Tighten screw 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 the drive...

Страница 25: ...mbly 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 trig...

Страница 26: ...LED 5 Wire Feed Speed Control R1 Turn control clockwise to increase wire feed speed 6 MIG Torch Connection Connectionfor Euro style MIG gun 7 Work Lead Connection 956142715_5 5 1 2 3 4 5 6 7 5 2 Burn...

Страница 27: ...arameters V A and to change from manual to synergic MIG modes 11 Trigger Mode Button Use control to select desired trigger mode see Section 5 7 12 Wire Diameter Push Button Use control to Select desir...

Страница 28: ...ockwise to de crease value 8 Positive Percentage Input Line Voltage Adjustment Display Indicator A dash in the right segment of the meter and a flashing PL1 indicates the need for a positive correctio...

Страница 29: ...FS Trim Arc Length And Line Input Adjustment Control to change wire feed speed or amperage de pending upon which parameter is active Rotate voltage control to change voltage when voltage LED is lit Th...

Страница 30: ...T and 4T trigger methods work in both manual and synergic modes 4 Spool Gun Mode See Section 5 8 1 2 3 4 5 8 Spool Gun Mode DX Models Only 1 Spool Gun Mode Indicator LED Connect spool gun to 7 pin spo...

Страница 31: ...ding Wire Type Selection For Synergic MIG DX Models Only 1 Welding Wire Types 2 Welding Wire Type Button Press button to select desired wire type Fe ferris CrNi stainless steel Al aluminum or CuSi Cop...

Страница 32: ...operat or may need to adjust main weld ing parameters for specific arc characteristics Use setup button to select desired parameter voltage amperage or preset wire feed speed and lite cor responding...

Страница 33: ...te wire feed speed Use setup button to select desired parameter voltage amperage or preset wire feed speed and lite cor responding LED V A or The value of the selected parameter is displayed on meter...

Страница 34: ...1 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 jamm...

Страница 35: ...ory Authorized Service Agent check main transformer T1 for signs of winding failure Check continuity across windings and check connections Check secondary voltages Replace T1 if necessary Have Factory...

Страница 36: ...OM 246 691 Page 32 SECTION 7 ELECTRICAL DIAGRAMS 956142709 C Figure 7 1 Circuit Diagram for Migmatic 220 230 VAC...

Страница 37: ...OM 246 691 Page 33 956142710 B Figure 7 2 Circuit Diagram for Migmatic 250 230 400 VAC...

Страница 38: ...OM 246 691 Page 34 956142711 F Figure 7 3 Circuit Diagram for Migmatic 220 DX 230 VAC...

Страница 39: ...OM 246 691 Page 35 956142712 E Figure 7 4 Circuit Diagram for Migmatic 250 DX 230 400 VAC...

Страница 40: ...OM 246 691 Page 36 SECTION 8 PARTS LIST 956142718_2 5 A 1 2 3 4 5 6 7 19 8 10 9 10 11 12 13 21 21 14 15 16 17 18 19 20 Figure 7 1 Wrapper Assembly All Models...

Страница 41: ...eel 1 1 12 156122080 Cover right side 1 1 13 056054083 Wheel Caster front 80 O D 2 2 14 356029212 Nameplate lower front MigMatic 220 250 1 1 15 156118060 Plastic lower front MigMatic 220 250 1 1 16 65...

Страница 42: ...691 Page 38 7 6 5 4 3 2 1 44 43 42 41 40 39 38 37 36 35 30 29 11 10 9 8 12 13 14 18 19 20 21 22 23 24 25 26 27 28 31 32 33 34 45 46 47 48 49 50 51 52 53 54 956142716 Figure 7 2 Main Assembly for MigMa...

Страница 43: ...hms D 16 L90 1 29 000 178 937 Label warning electric shock 1 30 156 122 082 Plate baffle 1 31 SR1 056 050 156 Rectifier PMS 20 4 2F 1 32 TP1 056 159 026 Thermostat 100 10A 1 33 656 026 127 Hose gas br...

Страница 44: ...40 956142719 A 7 6 5 4 3 2 1 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 54 27 28 29 54 30 31 32 33 34 35 44 45 46 47 36 37 38 39 40 41 42 43 48 49 50 51 52 53 Figure 7 3 Main Assembly for...

Страница 45: ...57 098 018 Choke 230V D 7 340x60 Al 1 29 R4 056 059 285 Resistance 3ohms D 16 L 9 0 1 30 000 178 937 Label warning electric shock 1 31 156 122 082 Plate baffle 1 32 SR1 056 050 156 Rectifier PMS 20 4...

Страница 46: ...1 Page 42 956142717 7 6 5 4 3 2 1 14 13 12 11 10 9 8 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 44 45 46 47 48 49 50 51 52 53 42 43 41 40 39 38 37 33 34 35 36 Figure 7 4 Main Assembly for MigM...

Страница 47: ...2 Plate baffle 1 29 SR1 056 050 157 Rectifier PTS 24 3 2F 1 30 TP1 056 059 288 Thermostat 100 1 31 656 026 123 Hose gas braided black D 5x8 10 bar 1 32 156 005 146 Corner Seal plastic r 15 2 33 R2 056...

Страница 48: ...ge 44 956142720 A 7 6 5 4 3 2 1 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 53 28 29 30 31 32 33 34 35 42 41 40 39 37 38 36 43 44 45 46 47 48 49 50 51 52 Figure 7 5 Main Assembly for Mig...

Страница 49: ...0x60x150 Al 1 28 000178937 Label warning electric shock 1 29 156122082 Plate baffle 1 30 SR1 056050157 Rectifier PTS 24 3 2F 1 31 TP1 056059288 Thermostat 100 1 32 656026123 Hose gas braided black D 5...

Страница 50: ...Page 46 956142721_1 A 1 2 3 13 8 9 10 11 17 26 20 18 16 21 22 25 23 24 21 15 27 33 19 32 31 30 29 28 34 19 27 19 35 12 36 37 38 39 40 4 5 14 6 7 2 Figure 7 6 Drive Assembly Wire 2 Roll MigMatic 220 2...

Страница 51: ...112 Drive Roll upper pressure arm housing d 17x30 1 23 156033036 Bushing upper drive roll assembly 1 24 156013050 Key upper drive roll assembly 3x3 L 15 1 25 156003036 Gear upper drive roll assembly d...

Страница 52: ...ge 48 956142721_2 A 40 39 38 37 36 35 12 19 27 19 34 28 29 30 31 32 33 27 19 15 16 18 21 24 23 25 22 21 20 26 17 11 10 9 8 13 3 2 1 2 14 5 4 7 6 Figure 7 7 Drive Assembly Wire 2 Roll MigMatic 220 DX 2...

Страница 53: ...053112 Drive Roll upper pressure arm housing d 17x30 1 23 156033036 Bushing upper drive roll assembly 1 24 156013050 Key upper drive roll assembly 3x3 L 15 1 25 156003036 Gear upper drive roll assembl...

Страница 54: ...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 03...

Страница 55: ...ntrollers Powered Air Purifying Respirator PAPR Blower Unit No Labor Racks Running Gear and Trailers Subarc Wire Drive Assemblies Water Coolant Systems Work Stations Weld Tables No Labor 5 6 Months Pa...

Страница 56: ...y 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 Suppli...

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