Miller MIGMATIC 220 Owner's Manual
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Miller MIGMATIC 220 Owner's Manual

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MigMatic 220/250 Base/DX
OWNER'S MANUAL
R
CE
OM-246 691F
2015−06
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
Wire Feeder
File: MIG (GMAW)

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Summary of Contents for Miller MIGMATIC 220

  • Page 1 OM-246 691F 2015−06 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source Wire Feeder MigMatic 220/250 Base/DX OWNER’S MANUAL Visit our website at File: MIG (GMAW) www.MillerWelds.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    ..........5-3. Controls For MigMatic 220 DX / 250 DX .

  • Page 4: Declaration Of Conformity

    Council Directive(s) and Standard(s). Product/Apparatus Identification: Product Stock Number MIGMATIC 220, 230VAC 029015520 MIGMATIC 220 DX, 230VAC 029015521 MIGMATIC 250 230/400VAC 029015524 MIGMATIC 250 DX, 230/400VAC 029015525 Council Directives: ·2006/95/EC Low Voltage...

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2013−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

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

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 9: Section 2 − Definitions

    SECTION 2 − DEFINITIONS 2-1. Additional Safety Symbols And Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012−05 Protect yourself from electric shock by insulating yourself from work and ground.
  • Page 10 Do not weld on drums or any closed containers. Safe16 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility. Contact your local recycling office or your local distributor for further information. Safe37 2012−05 Disconnect input plug or power before working on machine.

  • Page 11: Miscellaneous Symbols And Definitions

    2-2. Miscellaneous Symbols And Definitions Rated Maximum Amperage Gas Output 1max Supply Current Maximum Volts 1eff Effective Gas Type Supply Current Alternating Conventional Voltage Input Current (AC) Load Voltage Direct Current Rated Welding Wire Feed Spool (DC) Current Remote Duty Cycle Wire Feed Percent Hertz...

  • Page 12: Section 3 − Specifications

    SECTION 3 − SPECIFICATIONS 3-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on back panel . Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 3-2.

  • Page 13: Duty Cycle And Overheating

    3-4. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding.

  • Page 14: Section 4 − Installaton

    SECTION 4 − INSTALLATON 4-1. Selecting A Location Do not move or operate unit where it could tip. Line Disconnect Device Locate unit near correct input pow- er supply. Do not move or operate unit Special installation may be where it could tip. required where gasoline or volatile liquids are present −...

  • Page 15: Installing Gas Supply

    4-2. Installing Gas Supply Chain gas cylinder to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. Regulator/Flow Gauge Install so face is vertical. Gas Hose Connection Flow Adjust Typical flow rate is 0.9 liters per minute.

  • Page 16: Installing Wire Spool And Adjusting Hub Tension

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

  • Page 17: Positioning Jumper Links (230/400V 3-Phase Models)

    4-4. Positioning Jumper Links (230/400V 3-Phase Models) Disconnect and lockout/tag- out input power before instal- ling or moving jumper links. Check input voltage available at site. Jumper Link Label Check label − only one is on unit. Jumper Links Move jumper links to match input voltage.

  • Page 18: Electrical Service Guide

    4-5. Electrical Service Guide Elec Serv 2014−01 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.
  • Page 19 Notes OM-246 691 Page 15...

  • Page 20: Connecting Input Power (1-Phase And 3-Phase)

    4-6. Connecting Input Power (1-Phase and 3-Phase) A. 1-Phase =GND/PE Earth Ground Tools Needed: input4 2012−05 − Ref. D4 OM-246 691 Page 16...
  • Page 21 Connecting 1-Phase Input Power (Continued) See rating label on unit and check input volt- Connect green or green/yellow grounding Installation must meet all National and age available at site. conductor to disconnect device grounding Local Codes − have only qualified per- terminal first.
  • Page 22 B. 3-Phase = GND/PE Earth Ground Tools Needed: input2 2012−05 − Ref. D5 OM-246 691 Page 18...
  • Page 23 Connecting 3-Phase Input Power (Continued) See rating label on unit and check input volt- Connect green or green/yellow grounding Installation must meet all National and age available at site. conductor to disconnect device grounding ter- Local Codes − have only qualified per- minal first.

  • Page 24: Installing Drive Rolls And Wire Guide

    4-7. Installing Drive Rolls And Wire Guide Inlet Wire Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 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 roll.

  • Page 25: Threading Welding Wire And Adjusting Pressure Roll Tension

    4-8. Threading Welding Wire And Adjusting Pressure Roll Tension Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling.

  • Page 26: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls For MigMatic 220/250 Power Switch S1 Use switch to turn power on and off. Voltage Control S2 Turn control clockwise to increase voltage. High Temperature Shutdown Light PL2 (Orange LED) Power Indicator Light PL1...

  • Page 27: Controls For Migmatic 220 Dx / 250 Dx

    5-3. Controls For MigMatic 220 DX / 250 DX Power Switch S1 Use switch to turn power on and off. Voltage Control S2 Turn control clockwise to increase voltage. High Temperature Shutdown Light PL2-(Orange LED) Power Indicator Light PL1 (White...

  • Page 28: Welding Power Source Input Line Voltage Adjustment (Dx Models Only)

    5-5. Welding Power Source Input Line Voltage Adjustment (DX Models Only) Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control R1 Wire Feed Speed Indicator Scale (Manual Mode) Input Line Voltage Adjustment Center Indicator (Synergic Mode) Input Line Voltage/Wire Speed Adjustment Indicator Scale (Synergic Mode) Before power up, turn control R1 to...

  • Page 29: Welding Power Source Setup Menu (Dx Models Only)

    5-6. Welding Power Source Setup Menu (DX Models Only) Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control R1 Synergic Mode Indicator Voltage LED Digital Display Meter Amperage LED Wire Feed Speed LED Setup Button Manual Mode Indicator Voltage Control 10 Trigger Mode Button Use setup button to select desired...

  • Page 30: Trigger Mode Selection (Dx Models Only)

    5-7. Trigger Mode Selection (DX Models Only) Always select a trigger mode. 2T Trigger Mode When trigger is pressed welding starts. When trigger is released, welding stops. 4T Trigger Mode When trigger is pressed, welding starts. When trigger is released, welding contin- ues.

  • Page 31: Welding Wire Diameter Selection For Synergic Mig (Dx Models Only)

    5-9. Welding Wire Diameter Selection For Synergic MIG (DX Models Only) Welding Wire Diameters Welding Wire Diameter Button Press button to select desired wire diameter: 0.6 mm, 0.8 mm, 1.0 mm, or 1.2 mm, and lite corresponding LED. 5-10. Welding Wire Type Selection For Synergic MIG (DX Models Only) Welding Wire Types Welding Wire Type Button Press button to select desired wire...

  • Page 32: Selecting Manual Mig Welding (Dx Models Only)

    5-12. Selecting Manual MIG Welding (DX Models Only) Setup Button Manual MIG Mode Indicator Press and hold setup button for ap- proximately 3 seconds to select manual MIG mode and lite indicator. Voltage Control S2 Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control R1 Digital Display Meter In Manual MIG mode, the operat-...

  • Page 33: Selecting Synergic Mig Welding (Dx Models Only)

    5-13. Selecting Synergic MIG Welding (DX Models Only) Setup Button Synergic MIG Mode Indicator Press and hold Setup button for ap- proximately 3 seconds to select syn- ergic MIG mode and lite indicator. Voltage Control S2 Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control R1 Digital Display Meter...

  • Page 34: Section 6 − Maintenance &Troubleshooting

    SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Maintain more often Disconnect power during severe conditions. before maintaining. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals 6 Months Remove drive roll and Blow out or vacuum inside.

  • Page 35: Troubleshooting

    6-4. Troubleshooting Trouble Remedy Be sure line disconnect switch is On (see Section 4-6). No weld output; wire does not feed. Replace building line fuse or reset circuit breaker if open (see Section 4-6). Reset circuit breaker CB1 (see Section 6-2). Secure gun trigger connections.

  • Page 36: Section 7 − Electrical Diagrams

    SECTION 7 − ELECTRICAL DIAGRAMS 956142709-C Figure 7-1. Circuit Diagram for Migmatic 220 (230 VAC) OM-246 691 Page 32...
  • Page 37 956142710-B Figure 7-2. Circuit Diagram for Migmatic 250 (230/400 VAC) OM-246 691 Page 33...
  • Page 38 956142711-F Figure 7-3. Circuit Diagram for Migmatic 220 DX (230 VAC) OM-246 691 Page 34...
  • Page 39 956142712-E Figure 7-4. Circuit Diagram for Migmatic 250 DX (230/400 VAC) OM-246 691 Page 35...

  • Page 40: Section 8 − Parts List

    SECTION 8 − PARTS LIST 956142718_2-5-A Figure 7-1. Wrapper Assembly, All Models OM-246 691 Page 36...
  • Page 41 ..356029209 Nameplate, upper, front, MigMatic 220 DX/250 DX ..... .
  • Page 42 956142716 Figure 7-2. Main Assembly for MigMatic 220 OM-246 691 Page 38...
  • Page 43 Dia. Part Mkgs. Description Quantity Figure 7-2. Main Assembly for MigMatic 220 ....156 012 138 Spool Holder, shaft ..........
  • Page 44 956142719-A Figure 7-3. Main Assembly for MigMatic 220 DX OM-246 691 Page 40...
  • Page 45 Part Item Dia. Mkgs. Description Figure 7-3. Main Assembly for MigMatic 220 DX ....156 012 138 Spool Holder, shaft ..........
  • Page 46 956142717 Figure 7-4. Main Assembly for MigMatic 250 OM-246 691 Page 42...
  • Page 47 ... 356 029 215 Nameplate, rear, input gas, MigMatic 220/250 .....
  • Page 48 956142720-A Figure 7-5. Main Assembly for MigMatic 250 DX OM-246 691 Page 44...
  • Page 49 ... . 356029215 Nameplate, rear, input gas, MigMatic 220/250 .....
  • Page 50 956142721_1-A Figure 7-6. Drive Assembly, Wire (2 Roll) − MigMatic 220/250 Models OM-246 691 Page 46...
  • Page 51 Part Mkgs. Description Quantity Figure 7-6. Drive Assembly, Wire (2 Roll) − MigMatic 220/250 Models ... 056126079 Motor, 24VDC, 60W, 5300 rpm ......... .
  • Page 52 956142721_2-A Figure 7-7. Drive Assembly, Wire (2 Roll) − MigMatic 220 DX/250 DX Models OM-246 691 Page 48...
  • Page 53 Part Mkgs. Description Quantity Figure 7-7. Drive Assembly, Wire (2 Roll) − MigMatic 220 DX/250 DX Models ... 056126084 Motor, 24VDC, 60W, 5300 rpm ......... .
  • Page 54 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 55 Effective January 1, 2015 (Equipment with a serial number preface of MF or newer) 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 90 Days —...
  • Page 56 File a claim for loss or damage during Phone: 39 (0) 2982901 Fax: 39 (0) 298290-203 shipment. email: miller@itw−welding.it For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2015 Miller Electric Mfg. Co. 2015−01...

This manual is also suitable for:

Migmatic 250Migmatic 250dxMigmatic 220dx

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