Related Manuals for Miller Electric OM-229 038D
Summary of Contents for Miller Electric OM-229 038D
- Page 1 Migmatic 221/253 OM-229 038D 2007−04 Effective with serial number 226 214 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source Wire Feeder...
- Page 2 Warranty and service information for your particular model 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2. - 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). Manufacturer: ITW Welding Products Italy S.r.l. Via Privata Iseo 6/E 20098 San Giuliano Milanese, Italy Phone: 39(02)98290-1 European Contact Signature: Migmatic 221/253 Declares that this product:...
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Page 5: Section 1 − Safety Precautions - Read Before Using
DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment. - 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.
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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: Principal Safety Standards
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). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard F4.1 from Global... -
Page 9: Section 2 − Definitions
SECTION 2 − DEFINITIONS Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric shock by insulating yourself from work and ground. - Page 10 OM-229 038 Page 6 S-176 106 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Read the Owner’s Manual before working on this machine. Consult rating label for input power requirements, and check power available at the...
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Page 11: Weee Label
2-1. WEEE Label Warning! Watch Out! There are possible hazards as shown by the symbols. Electrical shock from wiring can kill. Read Owner’s Manual before working on this machine Wear approved safety glasses Electrode Positive (Straight Polarity) Electrode Negative (reverse Poalrity) Do not discard this product with general waste. -
Page 12: Section 3 − Installation
SECTION 3 − INSTALLATION 3-1. Specifications Rated Output Rated Output 100% Model 90 A 18.5 V Wire feed speed range 1.3 mpm to 20 mpm. * While idling Rated Output Rated Output 100% Model 145 A 21.0 V Wire feed speed range 1.3 mpm to 20 mpm. * While idling 3-2. -
Page 13: Volt-Ampere Curves
3-3. Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. 3-4. Installing Gas Supply Model 221 Argon Gas Model 253 Chain gas cylinder to running gear, wall, or other stationary support so cylinder cannot fall and break off... -
Page 14: Installing Wire Spool And Adjusting Hub Tension
3-5. Installing Wire Spool and Adjusting Hub Tension When a slight force is needed to turn spool, tension is set. 3-6. Positoning Jumper Links (230/400V 3-Phase Models) OM-229 038 Page 10 Use compression spring with 200 mm (8 in) spools. Tools Needed: 24 mm (15/16 in) -
Page 15: Electrical Service Guide
3-7. Electrical Service Guide Migmatic Model Input Voltage Input Amperes at Rated Output Max Recommended Standard Fuse or Circuit Breaker Rating in Amperes ** Input Conductor Size in mm ** Grounding Conductor Size in mm ** Power cord supplied with the unit is sized for 230V operation. Larger power cord may be required for cable lengths greater than 3 meters. Consult national and local regulations. - Page 16 B. 3-Phase Tools Needed: OM-229 038 Page 12 = GND/PE Earth Ground Y Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Y Disconnect and lockout/tagout in- put power before connecting input conductors from unit.
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Page 17: Installing Drive Rolls And Wire Guide
3-9. Installing Drive Rolls and Wire Guide Tools Needed: 5/64 in 7/16 in Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. Anti-Wear Guide Install guide as shown. Drive Roll The drive roll consists of two differ- ent sized grooves. -
Page 18: Threading Welding Wire And Adjusting Pressure Roll Tension
3-10. Threading Welding Wire and Adjusting Pressure Roll Tension Open pressure assembly. Tighten Close and tighten pressure assembly, and let go of wire. Press gun trigger until wire comes out of gun. Reinstall contact tip and nozzle OM-229 038 Page 14 Hold wire tightly to keep it from unraveling. -
Page 19: Using Gun/Cable Holder
3-11. Using Gun/Cable Holder 3-12. Setting Gun Polarity for Wire Type (Optional) Press latch down to release and open door. Provides storage space for gas nozzles, contact tips, gas diffusers. For solid steel, stainless steel, alu- minum, or flux core with gas, wires (GMAW). -
Page 20: Section 4 − Operation
SECTION 4 − OPERATION 4-1. Controls for Migmatic 221/253 4-2. Burnback and Spot Weld Timer Controls OM-229 038 Page 16 Power Switch Voltage Control Turn control clockwise to increase voltage. High Temperature Shutdown Light (Orange LED) Digital Display* Volts/Amps/Wire Feed Speed with last value hold function. -
Page 21: Section 5 − Maintenance &Troubleshooting
SECTION 5 − MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance 3 Months Replace unreadable labels Clean and tighten weld terminals 6 Months Blow out or vacuum inside. 5-2. Circuit Breaker CB1 5-3. Unit Overload Thermal switches TP1 in XFMR and TP2 in SR1 protect the unit from damage due to overheating. If the thermal indica- tor illuminates, wait for unit to cool allowing fan motor to run before trying to weld. -
Page 22: Troubleshooting
5-4. Troubleshooting Trouble Remedy Be sure line disconnect switch is On (see Section 3-8). No weld output; wire does not feed. Replace building line fuse or reset circuit breaker if open. Reset circuit breaker CB1 (see Section 5-2). Secure gun trigger connections. Check continuity of power switch S1 and replace if necessary. - Page 23 Notes OM-229 038 Page 19...
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Page 24: Section 6 − Electrical Diagrams
SECTION 6 − ELECTRICAL DIAGRAMS WARNING Do not touch live electrical parts. Disconnect input power or stop engine before servicing. Do not operate with covers removed. Have only qualified persons install, use, or Electric Shock service this unit. Hazard Figure 6-1. Circuit Diagram for Migmatic 221 OM-229 038 Page 20 September 21, 2006... - Page 25 WARNING Do not touch live electrical parts. Disconnect input power or stop engine before servicing. Do not operate with covers removed. Have only qualified persons install, use, or Electric Shock service this unit. Hazard Figure 6-2. Circuit Diagram for Migmatic 253 (400 VAC) September 21, 2006 OM-229 038 Page 21...
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Page 26: Section 7 − Parts List
SECTION 7 − PARTS LIST Figure 7-1. Wrapper Assembly, All Models OM-229 038 Page 22... - Page 27 Item Part Figure 7-1. Wrapper Assembly, All Models ..156034005 Catch, side panel ..156122062 Side Panel, hinged ..156034004 Hinge .
- Page 28 Figure 7-2. Main Assembly for Migmatic 221 OM-229 038 Page 24...
- Page 29 Item Dia. Part Mkgs. Figure 7-2. Main Assembly for Migmatic 221 ....956142538 ....000186436 .
- Page 30 Figure 7-3. Main Assembly for Migmatic 253 OM-229 038 Page 26...
- Page 31 Item Dia. Part Mkgs....956142538 ....000186436 ..
- Page 32 Table 7-1. Drive Roll And Wire Guide Kits (2 Roll Models) 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...
- Page 34 Notes...
- Page 35 Effective January 1, 2007 This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, ITW Welding Products Italy S.r.l., 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 File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2007 Miller Electric Mfg. Co. 1/07 TW Welding Products Italy S.r.l. Via Privata Iseo, 6/E 20098 San Giuliano Milanese, Italy...