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

Miller I-22 CE Owner's Manual

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www.MillerWelds.com
I-22 & I-24
OM-186 895AD
2011−10
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
CE
File: MIG (GMAW)

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Summary of Contents for Miller I-22 CE

  • Page 1 OM-186 895AD 2011−10 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder I-22 & I-24 File: MIG (GMAW) Visit our website at www.MillerWelds.com...
  • Page 2 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

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. 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).

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−01 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • 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 oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

  • 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 For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

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

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Fermer l’alimentation du gaz comprimé en cas endommagée, elle peut exploser.

  • Page 12: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 14 OM-186 895 Page 10...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. WEEE Label (For Products Sold Within The EU) Do not discard product (where ap- plicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collec- tion facility. Contact your local recycling office or your local distributor for further information.

  • Page 16: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. 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. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

  • Page 17: Site Selection

    4-5. Site Selection Do not put feeder where welding wire hits cylinder. Do not move or operate equipment when it could tip. Manually use handle to move or briefly lift feeder. Do not use lifting hook or other devices to lift or suspend feeder by the handle.

  • Page 18: Equipment Connection Diagrams

    4-6. 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) Work 115VAC Contactor 4-7. 14-Pin Receptacle, Shielding Gas And Optional Volt Sense Lead Gas Hose With 5/8-18 Right- hand Thread Fittings (Cus- tomer Supplied)

  • Page 19: 14-Pin Receptacle Information

    4-8. 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 20: Optional Meter Circuit Board Settings

    4-10. 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 21: Motor Start/Burnback Control

    4-11. 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 22: Installing Wire Guide And Drive Roll

    4-12. 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 23: Installing And Threading Welding Wire

    4-13. 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 24: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. 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 25: Optional Side Panel Controls

    5-2. 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 26: Overload Protection

    6-2. Overload Protection Turn Off wire feeder and welding power source. Stop engine on welding generator. Supplementary Protector CB1 protects wire feeder from overload. Correct problem and manually reset supplementary protector. 801 921-C 6-3. Troubleshooting Trouble Remedy Wire does not feed, unit completely inop- Turn Power switch On.

  • Page 27: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM 210 937-A Figure 7-1. Circuit Diagram For Wire Feeder With Optional Equipment OM-186 895 Page 23...

  • Page 28: Section 8 − Parts List

    SECTION 8 − PARTS LIST Figure 8-2 & Figure 8-3 − Figure 8-1. Main Assembly Hardware is common and not available unless listed. 801 990-H OM-186 895 Page 24...
  • Page 29 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ....089 899 . . . Latch ............
  • Page 30 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly (Continued) ..240 356 . . . Circuit Card Assy, Control (Consisting Of) ......
  • Page 31 Item Dia. Part Mkgs. Description Quantity Figure 8-2. Drive Assembly, Wire (2 Drive Roll) (Fig 8-1 Item 49) ....602 009 . . . Screw, .250-20 X 1.250 Soc Hd Hex Gr 8 .
  • Page 32 Item Dia. Part Mkgs. Description Quantity Figure 8-3. Drive Assembly, Wire (4 Drive Roll) (Fig 8-1 Item 49) ....602 009 . . . Screw, .250-20 X 1.250 Soc Hd Hex Gr 8 .
  • Page 33 Table 8-1. Drive Roll And Wire Guide Kits (2 Drive Roll) 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 34 Table 8-2. Drive Roll & Wire Guide Kits (4 Drive Roll) 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 35 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 Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
  • Page 36 Contact the Delivering Carrier to: 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.  ORIGINAL INSTRUCTIONS − PRINTED IN USA 2011 Miller Electric Mfg. Co. 2011−01...

This manual is also suitable for:

I-24 ce

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