Miller Electric I-22A & I-24A Owner's Manual
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Miller Electric I-22A & I-24A Owner's Manual

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www.MillerWelds.com
I-22A & I-24A
OM-186 895G
June 1999
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder

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Summary of Contents for Miller Electric I-22A & I-24A

  • Page 1 I-22A & I-24A Visit our website at www.MillerWelds.com OM-186 895G June 1999 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder...
  • Page 2 ISO 9001 Quality service information for your particular model System Standard. are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.

  • Page 3: Table Of Contents

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage 1-2. Arc Welding Hazards 1-3. Additional Symbols For Installation, Operation, And Maintenance WARNING 1-4. Principal Safety Standards 1-5. EMF Information This product, when used SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT UTILISATION for welding or cutting, 1-1.
  • Page 4 Declaration of Conformity for European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA I-22A And I-24A...

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 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. 1-2.
  • Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    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.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’...

  • Page 9: Section 1 − Consignes De Securite − Lire Avant Utilisation

    SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. Signifie NOTA ;...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur 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.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. D Ne pas placer l’appareil sur, au-dessus ou à proxi- mité de surfaces infllammables. D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique −...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

  • Page 13: Section 2 − Definitions

    SECTION 2 − DEFINITIONS 2-1. Warning Label Definitions S-178 936 A. Warning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. Welding wire and drive parts are at welding voltage during operation −...

  • Page 14: Rating Label For Ce Products

    2-2. Rating Label For CE Products 2-3. Symbols And Definitions NOTE Some symbols are found only on CE products. Amperes Degree Of Protection Purge Burnback Time Load Voltage OM-186 895 Page 10 S/N: 50/60 IP 23 X 100 % Volts Hertz Primary Voltage Spot Weld Time...

  • Page 15: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Specifications Welding Type of Input Wire Feed Power Power Speed Range Source Type Constant Voltage 24 Volts AC (CV) DC With 1.9 To 19 mpm Single Phase 14-Pin And 7 Amperes 50/60 (75 to 750 ipm) Contactor Control 3-2.

  • Page 16: Gun Recommendation Table

    3-3. Gun Recommendation Table Process GMAW − Hard or Corded Wires FCAW − Self-Shielding Wires 3-4. Equipment Connection Diagrams 3-5. 14-Pin Receptacle, Shielding Gas And Optional Volt Sense Lead Tools Needed: 5/8, 11/16 in OM-186 895 Page 12 M25 Or M40 GA-40GL 115VAC Contactor...

  • Page 17: 14-Pin Receptacle Information

    3-6. 14-Pin Receptacle Information Pin* *The remaining pins are not used. 3-7. Connecting Welding Gun And Weld Cable Pin Information 24 volts ac with respect to pin G. Contact closure to A completes 24 volts ac contactor control circuit. Circuit common for 24 volts AC circuit. +10 volts dc output to remote control with respect to pin D.

  • Page 18: Optional Meter Circuit Board Settings

    3-8. Optional Meter Circuit Board Settings X Means switch position does not affect specified function. Means switch must be in this position. Voltage Sensing Function Arc Voltage Sensing Using Voltage Sensing Lead For Welding Power Source That Does Not Support Pins F And H Arc Voltage Sensing Using Feedback From Welding Power Source That Does Support Tools Needed:...

  • Page 19: Motor Start/Burnback Control

    3-9. Motor Start/Burnback Control Tools Needed: Non-Conductive 1/4 in To change wire feed starting speed proceed as follows: Turn Off unit and welding power source. Remove wrapper. Motor Board PC1 Motor Start Control Potentiometer R73 Remove protective white rubber cap before making adjustment. Adjust potentiometer R73 using a small nonconductive screwdriver.

  • Page 20: 3-10.Installing Wire Guide And Drive Roll

    3-10. Installing Wire Guide And Drive Roll Install and secure inlet wire guide either assembly, 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.

  • Page 21: 3-11.Installing And Threading Welding Wire

    3-11. Installing And Threading Welding Wire Tighten WOOD Retaining Ring Hub Tension Adjustment Nut If necessary, move hub on support for use of different size wire spool. Remove retaining ring, and install spool so hub pin fits spool hole. Reinstall retaining ring. Adjust tension nut so wire is taut when wire feed stops.

  • Page 22: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Front Panel Controls OM-186 895 Page 18 Optional Voltage/Wire Speed Meter Optional Voltage/Wire Speed Switch Use to choose volts or wire feed speed display. Optional Remote Voltage Control Use to set welding power source voltage at the wire feeder. Numbers are for reference only.

  • Page 23: Optional Side Panel Controls

    4-2. Optional Side Panel Controls SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Replace Unreadable Labels 14-Pin Cord Y Disconnect power before maintaining. 3 Months Repair Or Replace Cracked Weld Cable Gun Cable Gas Hose 6 Months Clean Drive Rolls Preflow Control Control sets time gas flows before...

  • Page 24: Overload Protection

    5-2. Overload Protection 5-3. Troubleshooting Trouble Wire does not feed, unit completely inop- Turn Power switch On. erative. Check 14−pin receptacle RC9 connections. Check input power. Wire does not feed. Check circuit breaker CB1. (see Section 5-2) Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s Manual.

  • Page 25: Section 6 − Electrical Diagram

    SECTION 6 − ELECTRICAL DIAGRAM 186 738-B Figure 6-1. Circuit Diagram For Wire Feeder With Optional Equipment OM-186 895 Page 21...

  • Page 26: Section 7 − Parts List

    SECTION 7 − PARTS LIST Figure 7-2 & Figure 7-3 − Hardware is common and not available unless listed. OM-186 895 Page 22 Figure 7-1. Main Assembly 801 990-C...
  • Page 27 Item Dia. Part Mkgs....089 899 ....+186 674 .
  • Page 28 Item Dia. Part Mkgs....192 955 ..LED1 ♦179 203 ..
  • Page 29 Item Dia. Part Mkgs....602 009 ....172 075 .
  • Page 30 Item Dia. Part Mkgs....602 009 ....172 075 .
  • Page 31 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.
  • Page 32 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.
  • Page 33 Notes OM-186 895 Page 29...
  • Page 34 Notes OM-186 895 Page 30...
  • Page 35 Miller distributor. LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 36: Options And Accessories

    Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. © 1999 Miller Electric Mfg. Co. 9/98 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA &...

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I-22aI-24a

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