Miller I-22 Owner's Manual
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Miller I-22 Owner's Manual

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I-22 & I-24
OM-186 895M
August 2001
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder

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Summary of Contents for Miller I-22

  • Page 1 OM-186 895M August 2001 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder I-22 & I-24 Visit our website at www.MillerWelds.com...
  • Page 2 – every power source from This Owner’s Manual is designed to help you get the most out of your Miller is backed by the most Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the business.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......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 som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • 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 cause injury. 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: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

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

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • 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 DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • 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- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions 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 – keep hands and metal objects clear.

  • Page 14: Rating Label For Ce Products

    2-2. Rating Label For CE Products S/N: 50/60 IP 21 X 100 % 178 794-A 2-3. Symbols And Definitions NOTE Some symbols are found only on CE products. Input Output Amperes Volts Alternating Current Duty Cycle Degree Of Hertz Circuit Breaker Wire Feed Protection Gas Metal Arc...

  • Page 15: Section 3 - Installation

    SECTION 3 – INSTALLATION 3-1. Specifications Welding Wire Welding Type of Input Wire Feed Overall Power Diameter Circuit Weight Power Speed Range Rating Dimensions Source Type Range Rating Length: 597 mm 0.6 To 2 mm 100 Volts, Constant Voltage (23-1/2 in) 24 Volts AC (.023 To 5/64 in) 500 Amperes,...

  • Page 16: Gun Recommendation Table

    3-3. Gun Recommendation Table Process GMAW – Hard or Corded Wires M25 Or M40 FCAW – Self-Shielding Wires GA-40GL 3-4. Equipment Connection Diagrams CV Welding Power Source With 24 VAC Power CV Welding Power Source Without 24 VAC Power 115 Volts AC /24 Volts AC Power Adapter 14-Pin Control Cord Weld Cable (Required)

  • Page 17: 14-Pin Receptacle Information

    3-6. 14-Pin Receptacle Information Pin* 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. Remote control circuit common.

  • Page 18: Optional Meter Circuit Board Settings

    3-8. Optional Meter Circuit Board Settings Meter Circuit Board DIP Switch S2 Set DIP switch S2 for type of welding power source, and desired wire feed speed display (see illustration). Reinstall wrapper. X Means switch position does not affect specified function. Means switch must be in this position.

  • Page 19: Motor Start/Burnback Control

    3-9. Motor Start/Burnback Control 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 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 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 Preflow Control Control sets time gas flows before welding wire is energized. Time range is 0 to 5 seconds. Postflow Control Control sets time gas flows after completion of burnback. Time range is 0 to 5 seconds. Spot Time Control Factory set for 0.25 to 5 seconds of spot time.

  • Page 24: Overload Protection

    5-2. Overload Protection Y Turn Off wire feeder and welding power source. Stop engine welding generator. Circuit Breaker CB1 CB1 protects wire feeder from over- load. Correct problem and manually reset breaker. 801 921-C 5-3. Troubleshooting Trouble Remedy Wire does not feed, unit completely inop- Turn Power switch On.

  • Page 25: Section 6 - Electrical Diagram

    SECTION 6 – ELECTRICAL DIAGRAM 186 738–E 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 801 990-E not available unless listed. Figure 7-1. Main Assembly OM-186 895 Page 22...
  • Page 27 ......(Prior to KK008806 for I-22 models, Prior to KK036472 for I-24 models) .
  • Page 28 Item Dia. Part Mkgs. Description Quantity Figure 7-1. Main Assembly (Continued) ♦186 268 ..CIRCUIT CARD, meter (consisting of) .......
  • Page 29 Item Dia. Part Mkgs. Description Quantity Figure 7-2. Drive Assembly, Wire (2 Drive Roll) (Fig 7-1 Item 48) ....602 009 . . . SCREW, .250-20 x 1.250 soc hd hex gr 8 .
  • Page 30 Item Dia. Part Mkgs. Description Quantity Figure 7-3. Drive Assembly, Wire(4 Drive Roll) (Fig 7-1 Item 48) ....602 009 . . . SCREW, .250-20 x 1.250 soc hd hex gr 8 .
  • 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 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...

  • Page 36: Options And Accessories

    Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate 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...

This manual is also suitable for:

I-24

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