OM-193 472N 2006−05 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder 22A, 24A File: MIG (GMAW) Visit our website at www.MillerWelds.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We 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 afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch 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 Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
ARC RAYS can burn eyes and skin. 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. D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. 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. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette procédure comporte des risques possibles ! Les dangers éventuels sont représentés par les symboles graphiques joints. Y Indique un message de sécurité particulier . Signifie NOTE ; n’est pas relatif à la sécurité. 2-2.
LES RAYONS D’ARC peuvent entraîner des brûlures aux yeux et à la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. D Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service.
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site Internet : www.csa-international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.
SECTION 3 − INSTALLATION 3-1. Specifications Type of Input Power Welding Power Source Type 24 Volts AC Single Phase 7 Amperes 50/60 Hz Constant Voltage (CV) DC With 14-Pin And Contactor Control Wire Feed Speed Range 75 to 750 ipm (1.9 To 19 mpm) Wire Diameter Range Welding Circuit Rating .023 To 5/64 in (0.6 To 2 mm) Max Spool Weight: 60 lb (27 kg) Overall Dimensions Weight Length: 23-1/2 in (597 mm) 100 Volts, 500 Amperes, 100% Duty Cycle Width: 10-3/4 in (273 mm) 35 lb (15.
3-3. Gun Recommendation Table Process Gun GMAW − Hard or Corded Wires M25 Or M40 FCAW − Self-Shielding Wires GA-40GL 3-4. Equipment Connection Diagrams 1 CV Welding Power Source With 24 VAC Power 2 CV Welding Power Source Without 24 VAC Power 115 Volts AC /24 Volts AC Power Adapter 14-Pin Control Cord Weld Cable (Required) Work 3 4 5 6 1 4 6 3 5 2 115VAC 4 Contactor 6 5 3-5.
3-6. 14-Pin Plug Information Pin* J I N H G A K B L M F C E D Pin Information A 24 volts ac with respect to pin G. B Contact closure to A completes 24 volts ac contactor control circuit. G Circuit common for 24 volts AC circuit. C +10 volts dc output to remote control with respect to pin D. D Remote control circuit common. E 0 to +10 volts dc input command signal from remote control with respect to pin D.
3-8. Optional Meter Circuit Board Settings 1 Meter Circuit Board 2 DIP Switch S2 Set DIP switch S2 for type of welding power source, and desired wire feed speed display (see illustration). Reinstall wrapper. 1 2 1 2 X Means switch position does not affect specified function. . Means switch must be in this position.
3-9. Motor Start/Burnback Control To change wire feed starting speed proceed as follows: Turn Off unit and welding power source. 1 Remove wrapper. 1 2 Motor Board PC1 Motor Start Control Potentiometer R73 Remove protective white rubber cap before making adjustment. Adjust potentiometer R73 using a small nonconductive screwdriver. Rotate potentiometer clockwise to increase time it takes the motor to ramp up to speed.
3-10. Installing Wire Guide And Drive Roll Install and secure inlet wire guide on either assembly, and intermediate wire guide on 4 drive roll assembly only. Install drive rolls and turn drive roll nut one click. During maintenance intervals, remove drive rolls, and clean grooves using a wire brush. Check groove of drive roll for pitting or increase in the depth of the groove indicating drive roll is worn out.
3-11. Installing And Threading Welding Wire 1 2 Retaining Ring Hub Tension Adjustment Nut If necessary, move hub on support for use of different size wire spool. 1 2 Remove retaining ring, and install spool so hub pin fits spool hole. Reinstall retaining ring. 3 Adjust tension nut so wire is taut when wire feed stops. 3 Pressure Assembly Adjustment Knob Lay gun cable out straight. A Open pressure assembly, hold wire tightly, and cut off end. Push wire through guides into gun.
SECTION 4 − OPERATION 4-1. Front Panel Controls 1 Optional Voltage/Wire Speed Meter 2 Optional Voltage/Wire Speed Switch 1 2 Use to choose volts or wire feed speed display. 3 3 4 Optional Remote Voltage Control Use to set welding power source voltage at the wire feeder. Numbers are for reference only. 4 Wire Speed Control 5 Jog/Purge Switch Use Jog position to momentarily feed welding wire at speed set on Wire Speed control without energizing welding circuit or shielding gas valve.
4-2. Optional Side Panel Controls 1 Preflow Control Control sets time gas flows before welding wire is energized. Time range is 0 to 5 seconds. 4 1 2 Postflow Control Control sets time gas flows after completion of burnback. Time range is 0 to 5 seconds. 3 Spot Time Control Factory set for 0.25 to 5 seconds of spot time. Rotating knob fully counterclockwise selects an untimed continuous weld. 2 4 Run-In Control Use control to set wire feed speed before arc initiation. Close side door. 3 Ref.
5-2. Overload Protection Y Turn Off wire feeder and welding power source. Stop engine on welding generator. 1 1 Circuit Breaker CB1 CB1 protects wire feeder from overload. Correct problem and manually reset breaker. 802 349-A 5-3. Troubleshooting Trouble Remedy Wire does not feed, unit completely inop- Turn Power switch On. erative. Check 14−pin plug PLG2 connections. Check input power. Wire does not feed. Check circuit breaker CB1. (see Section 5-2) Check gun trigger connection at wire feeder.
SECTION 6 − ELECTRICAL DIAGRAM 210 430-A Figure 6-1.
SECTION 7 − PARTS LIST . Hardware is common and not available unless listed. 5 6 7 4 8 9 3 10 11 2 10 1 9 12 13 14 42 41 15 18 Figure 7-2 & Figure 7-3 45 40 16 17 44 43 19 20 39 21 22 38 46 37 25 23 24 26 33 35 36 34 31 32 Figure 7.1.
Item No. Diagram marking Part No. Description Quantity Figure 7-1. Main Assembly . . . 1 . . . . . . . . . . . . . 089 899 . . . LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . . . +198 650 . . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . 126 873 . . . BUMPER . . . . . . . . . . . . . . . .
Item No. Diagram marking Part No. Description Quantity Figure 7-1. Main Assembly (Continued) . . . . . . . . . . . . . . . . . ♦115 443 . . . STAND-OFF, 6-32 x .750 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 33 . . . . . . . . . . . . . 197 328 . . . CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . 183 914 . . . BLANK, snap-in nyl 1.250 mtg hole . . . . . . .
Item No. Diagram marking Part No. Description Quantity Figure 7-2. Drive Assembly, Wire (2 Drive Roll) (Fig 7-1 Item 40) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. .
Item No. Diagram marking Part No. Description Quantity Figure 7-3. Drive Assembly, Wire (4 Drive Roll) (Fig 7-1 Item 40) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ........
Table 7-1. Drive Roll And Wire Guide Kits (2 Drive Roll) NOTE 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 wires. 5. Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved).
Table 7-2. Drive Roll & Wire Guide Kits (4 Drive Roll) NOTE 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 wires. 5. Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved). Wire Diameter Fraction Decimal .
Effective January 1, 2006 (Equipment with a serial number preface of “LG” or newer) Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You 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 of the distributor and Miller is there to help you, every step of the way.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co.
