OM-250 884A 2011−01 Processes MIG (GMAW) Welding Description Feeder Gun MigMatic 220DX/250DX Spool Gun R CE 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.
DECLARATION OF CONFORMITY for European Community (CE marked) products. ITW Welding Products Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010−03 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator.
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. FALLING EQUIPMENT can injure. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SECTION 2 − INSTALLATION 2-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) ! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
2-3. Connecting Spool Gun To MigMatic 220DX/250DX . See the MigMatic 220DX/250DX Owner’s Manual for additional information on connecting and operating the spool gun. . The spool gun works only with the welding power source in the Manual mode and Wire feed speed is controlled by the spool gun Wire Speed control (see Section 3-1). If the welding power source is in the Synergic mode, the spool gun works only with Aluminum wire. .
2-4. Opening Cover 1 1 Thumbscrew 2 Cover Loosen thumbscrew and rotate cover open. 2 Ref.
2-5. Installing Wire Spool And Threading Welding Wire 1 2 3 Cover Canister Thumbscrew (Cover) Loosen thumbscrew and remvoe cover. 4 Wire Spool Loosen wire from spool, cut off bent wire, and pull 6 in. (150 mm) of wire off spool. 5 Pressure Roll Assembly Press arm inward to open pressure roll assembly. 6 6 7 8 7 Wire Inlet Guide Drive Roll Groove Contact Tip Thread wire through wire inlet guide, along drive roll groove, and out contact tip. 5 Install spool so wire feeds off bottom.
2-6. Adjusting Drive Roll And Spool Brake Pressure 1 2 Cover Thumbscrew Loosen thumbscrew and rotate cover open. 3 Spool Cut welding wire off at contact tip. Retract wire onto spool and secure wire. 4 5 Spool Brake Thumbnut Grasp spool in one hand and turn spool while adjusting spool brake thumbnut. When a slight force is needed to turn spool, tension is set. Do not overtighten. Thread welding wire (see Section 2-5).
2-7. Adjusting Position Of Spool Canister Tools Needed: The canister can be moved to three positions. Before welding, move the spool canister to the position that allows the gun to be handled most comfortably. Spool Wire Position 1 Canister Adjustment Screw Loosen screw and move spool canister to the desired position. Tighten screw. Note position of canister. 1 Spool Wire Position Note position of canister. 1 Ref.
SECTION 3 − OPERATION 3-1. Controls 1 Trigger Press trigger to energize welding power source contactor (if applicable), start shielding gas flow, and begin wire feed. For shielding gas preflow and postflow, lightly press trigger before and after welding. 2 Wire Speed Control Use control to adjust wire feed speed. Rotate control clockwise to increase wire feed speed. . See the MigMatic 220DX/250DX Owner’s Manual for additional information on connecting and operating the spool gun. .
SECTION 4 − MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance ! . Maintain more often Disconnect power before maintaining. during severe conditions. 3 Months Replace Damaged Or Unreadable Labels Clean And Tighten Weld Terminals Replace Damage Gas Hose Repair Or Replace Cracked Cables And Cords 6 Months Blow Out Or Vacuum Inside Clean Drive Rolls 4-2. Changing Gun Contact Tip ! Turn off welding power source. 1 Nozzle 2 Contact Tip 3 Tension Spring Remove nozzle Unscrew contact tip.
4-3. Replacing Inlet Guide 5 6 ! Turn off source. 1 Pressure Roll Assembly welding power Cut off welding wire where it enters pressure roll assembly area. 2 Nozzle Pull wire out nozzle end. 4 3 4 Thumbscrew Cover Loosen thumbscrew and remove cover. 5 6 2 Wire Spool Spool Brake Thumbnut Loosen thumbnut, retract wire onto spool, secure wire, and remove spool. 7 3 Inlet Guide Use pliers to remove inlet guide. Install new guide. Reinstall spool and thread welding wire (see Section 2-5).
4-4. Gun Drive Assembly Maintenance ! Turn off source. welding power Retract wire onto spool. 1 Drive Roll Cap Rotate drive roller cap counterclockwise and remove it from the drive roller. 2 Drive Roll Loosen set screw and remove drive roll. Use wire brush to clean drive roll. Install drive roll with desired groove down; rotate drive roll so set screw faces flat side of shaft. Tighten set screw. 3 4 Pressure Roll Assembly Bearing Open pressure roll assembly to access bearing.
SECTION 5 − ELECTRICAL DIAGRAM 956142723-A Figure 6-1.
1 2 24 3 OM-250 884 Page 16 Figure 7-1. Complete Assembly 4 25 24 25 5 6 39 25 7 26 24 25 8 27 26 21 20 9 10 18 26 22 28 12 29 13 14 11 19 17 15 23 30 31 16 26 32 36 35 34 33 26 37 14 38 not available unless listed. .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-1. Complete Assembly . . . 1 . . . . . . . . . 057054060 . . . 2 . . . . . . . . . 256095074 . . . . . . . . . . . . . . . 256095076 . . . 3 . . . . . . . . . 556081130 . . . 4 . . . . . . . . . 156032131 . . . 5 . . . . . . . . . 756033045 . . . 6 . . . . . . . . . 656026124 . . . 7 . . . . . . . . . 656033008 . . . 8 . . . . . . . . . 057017043 . . . 9 . . . . . . . . . 656021267 . . . 10 . . . . . . . . . 156019769 . . . 11 . . . . . . . . .
Notes
Effective January 1, 2011 (Equipment with a serial number preface of MB or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied.
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 Country Zip/Postal Code 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 Service and Repair Replacement Parts Owner’s Manuals ITW Welding Products Italy S.r.
