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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.
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Council Directive(s) and Standard(s). Product/Apparatus Identification: Product Stock Number MPi 220P 230VAC 059016014 Council Directives: 2014/35/EU Low Voltage 2014/30/EU Electromagnetic Compatibility 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment Standards: IEC 60974−1:2012 Arc Welding Equipment –...
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EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number MPi 220P CE 059016014 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standards IEC 62822− 1:2016, IEC 62822− 2:2016 Intended use...
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2018−01 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.
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D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.
D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.
H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.
SECTION 2 − DEFINITIONS 2-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. 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 2017−04 Protect yourself from electric shock by insulating yourself from work and ground.
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Disconnect input plug or power before working on machine. Safe5 2017−04 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 2017−04 Disconnect input plug or power before working on machine.
2-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Amperage Primary Voltage Gas Input Rated Maximum Gas Output Volts Supply Current 1max Maximum Alternating Voltage Input Effective Current (AC) 1eff Supply Current Direct Current Wire Feed Conventional Load (DC) Voltage...
SECTION 3 − SPECIFICATIONS 3-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the bottom . 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.
3-4. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. A. MIG 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 DC Amperes B.
3-5. Environmental Specifications A. IP Rating IP Rating IP22S This equipment is designed for indoor use and is not intended to be used or stored outside. IP22S 2014−06 B. Temperature Specifications Operating Temperature Range* Storage/Transportation Temperature Range −10 to 40°C (14 to 104°F) −20 to 55°C (−4 to 131°F) *Output is derated at temperatures above 40°C (104°F).
SECTION 4 − INSTALLATION 4-1. Selecting A Location Airflow Distance Requirements Do not move or operate unit where it could tip. Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.
4-2. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve.
4-3. Weld Output Terminals And Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable size.
4-6. Changing Polarity Lead Connections For Direct Current Electrode Positive (DCEP) Lead Connections For Direct Current Electrode Negative (DCEN) Always read and follow wire manufacturer’s recommended polarity and see Section 4-5. 956142881_2-A OM-253918 Page 14...
4-8. Changing Drive Rolls And Wire Inlet Guide Setscrew Inlet Wire Guide Loosen setscrew. Slide tip of guide as close to drive rolls as possible without touching. Tighten setscrew. 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.
4-9. Aligning Drive Rolls and Wire Guide Turn off and disconnect in- put power View is from top of drive rolls looking down with pressure assembly open. Correct Incorrect Drive Roll Securing Nut Drive Roll Wire Guide Welding Wire Drive Gear Insert screwdriver, and turn screw in or out until drive roll groove lines up with wire guide.
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4-11. Connecting 1-Phase 230 VAC Input Power (Continued) Installation must meet all National and See rating label on unit and check input volt- Connect green or green/yellow grounding Local Codes − have only qualified per- age available at site. conductor to disconnect device grounding sons make this installation.
SECTION 5 − OPERATION 5-1. Controls Power Switch S1 Use switch to turn power on and off. Wire Speed/Set-Up Adjustment Control Use control to adjust wire speed and change values while in the set-up mode. Amperage/Workpiece Thickness Adjustment Control Use control to adjust welding am- perage while in TIG and STICK mode (see Section 5-2 or 5-3) or workpiece thickness while in MIG...
5-3. Preparing Unit For TIG Welding Positive Weld Output Terminal Gun Trigger Receptacle Negative Weld Output Terminal Hot Start Adjustment Knob Amperage Adjustment Control Knob Digital Meter Display Process Selector Switch Welding Amperage Welding Voltage 10 TIG Welding Symbol 11 Set Amperage 12 Hot Start Adjustment Switch Prepare unit for TIG welding as fol- lows:...
5-5. Preparing Unit For Manual MIG (GMAW And FCAW) Welding Process To select MIG welding proceed as follows: Prepare unit according to Section 4. Use a cable with correct adapter, connect gun to the MIG gun con- nector. For GMAW process: Connect wire drive lead to positive output terminal.
5-6. Manual MIG Welding Set-Up Menu To enter MIG welding set-up menu, proceed as follows: Sequencer Set-Up P2 Push Button Wire Feed Speed (WFS) Adjustment Knob While in the set-up menu, use knob to change sequencer parameters. Sequencer Adjustment/Operator Point Setting P3 Push Buttons (See Section 5-16) Process Selection P1 Push...
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5-6. Manual MIG Welding Set-Up Menu (Continued) In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit transfers per second (provided no other changes are made) and increase the arc-on time. The increased arc-on time makes the welding puddle more fluid.
5-7. Trigger Mode And Spot Time Selection (MIG Process) Always select a trigger mode. Digital Display Meter Sequencer Set-Up P3 Push Buttons Wire Feed Speed (WFS) Adjustment Knob Sequencer Adjustment/Operator Point Setting P2 Push Button To select trigger mode and spot weld timer, proceed as follows: Press and hold P2 push button to enter into the set-up menu.
5-8. Preparing Unit For Synergic MIG (GMAW And FCAW) Welding Process To select MIG welding process, proceed as follows: Prepare unit according to Section 4. Use a cable with correct adapter, connect gun to the MIG gun con- nector. For GMAW process: Connect wire drive lead to positive output terminal.
5-9. Synergic MIG Welding Set-Up Menu To enter MIG welding set-up menu, proceed as follows: Sequencer Set-Up P2 Push Button Arc Length Control Knob While in the set-up menu, use knob to change sequencer parameters. Sequencer Adjustment/Operator Point Setting P3 Push Buttons (See Section 5-16) Process Selection P1 Push Button...
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5-9. Synergic MIG Welding Set-Up Menu (Continued) Percentage Of Weld Output Inductance Use Arc Length control knob to se- lect the percentage of welding in- ductance value. When selected, use the knob or sequencer P3 push buttons to change value. Default = 0% (min = −10%, max = +10%).
5-10. Preparing Unit For Synergic Pulsed MIG (GMAW And FCAW) Welding Process To select MIG welding process, proceed as follows: Prepare unit according to Section 4. Use a cable with correct adapter, connect gun to the MIG gun con- nector. For GMAW process: Connect wire drive lead to positive output terminal.
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5-10. Preparing Unit For Synergic Pulsed MIG (GMAW And FCAW) Welding Process (Continued) Set MIG welding process using pro- cess selection P1 push button. To enter synergic pulsed MIG mode, press and release sequencer set-up P2 push button. Use se- quencer adjustment P3 push but- tons until PULSED is displayed.
5-11. Synergic Pulsed MIG Welding Set-Up Menu To enter MIG welding set-up menu, proceed as follows: Sequencer Set-Up P2 Push Button Arc Length Control Knob While in the set-up menu, use knob to change sequencer parameters. Sequencer Adjustment/Operator Point Setting P3 Push Buttons (See Section 5-16) Process Selection P1 Push Button...
5-12. 4T Trigger Set-Up Menu (Synergic Pulsed MIG Welding Only) To enter 4T trigger set-up menu: Follow instructions listed in Section 5-7. Postflow Time (See Section 5-11) Arc Power (Hot Start) Percentage Percent increase of welding current to make arc start easier. When this item is selected, use the Arc Length control knob or Sequencer adjust- ment P3 push buttons to change...
5-13. Welding Wire Loading Settings Prepare unit for welding wire load- ing as follows: S Install wire spool and adjust hub tension (see Section 4-7). S Use proper drive rolls and wire guide (see Section 4-8). S Thread welding wire and adjust pressure roll tension (see Section 4-12).
Power Switch Use power switch to turn unit on. When Miller appears on the display, press and release sequencer set-up P2 push button. Basic set-up menu will be displayed. Press and hold P2 until OK is displayed by re- setting parameters.
5-16. Operator Point MIG Parameters Loading This setting is only available in MIG mode. It allows the operat- or to load and save desired specified weld parameters and recall them when required. Store parameters: Press and release P3 push buttons simultaneously to enter the operat- or point set-up menu.
4-10 under normal operating conditions. Power Switch Use power switch to turn unit on. When Miller appears on the display, press and release sequencer set-up P2 push button. Unit is at de- fault setting of H (high rated supply current I ).
5-18. Basic Set-Up Menu Parameters Settings Power Switch Use power switch to turn unit on. When Miller appears on the display, press and release sequencer set-up P2 push button. Basic set-up menu will be displayed. Initial Wire Feed Speed (WFS) Settings Press and release P2 push button to select desired parameter.
SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every Months l Unreadable Labels...
6-4. Troubleshooting A. MIG (GMAW) Welding Trouble Remedy Be sure line disconnect switch is On (see Section 4-11). No weld output; wire does not feed. Replace building line fuse or reset circuit breaker if open (see Section 4-11). Secure gun trigger connections (see welding gun Owner’s Manual). Check continuity of power switch S1 and replace if necessary.
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B. Stick (SMAW) Welding Trouble Remedy Hard starts, poor welding characterist- Use proper type and size of electrode. ics, unusual spattering. Check electrode polarity and reverse in necessary; check and correct poor connections Make sure a remote control is not connected. C.
SECTION 8 − GMAW WELDING (MIG) GUIDELINES 8-1. Typical GMAW (MIG) Process Connections Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Regulator/ Flowmeter Wire Feeder/...
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8-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trig- ger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is positioned cor- rectly on seam.
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8-5. Gun Movement During Welding Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Stringer Bead − Steady Movement Along Seam Weave Bead −...
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8-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long.
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8-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.
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8-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle. Unsteady hand.
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8-16. Common GMAW (MIG) Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. Application Short Short...
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8-17. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls. Wire feed motor operates, but wire does not feed. Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to match wire size and type if necessary.
SECTION 9 − STICK WELDING (SMAW) GUIDELINES 9-1. Stick Welding Procedure Weld current starts when electrode touches work- piece. Weld current can damage electronic parts in vehicles. Disconnect both battery Equipment Needed: Tools Needed: cables before welding on a vehicle. Place work clamp as close to the weld as possible.
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9-2. Electrode And Amperage Selection Chart 6010 DEEP 3/32 MIN. PREP, ROUGH HIGH SPATTER 6011 DEEP 6010 5/32 & 6013 EP,EN GENERAL 3/16 6011 7/32 SMOOTH, EASY, 7014 EP,EN FAST 1/16 LOW HYDROGEN, 7018 5/64 STRONG 3/32 FLAT SMOOTH, EASY, 7024 EP,EN 6013...
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9-4. Positioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle After learning to start and hold an arc, practice running beads of weld metal on flat plates using a full electrode. ° ° Hold the electrode nearly per- pendicular to the work, although tilting it ahead (in the direction of °...
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9-7. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Correct Angle Angle Too Large ° - ° Angle Too Small Electrode Angle Drag Spatter Arc Length Normal Too Long Too Short...
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9-10. Welding Groove (Butt) Joints Tack Welds Prevent butt joint distortion by tack welding the materials in position before final weld. Workpiece distortion occurs when heat is applied locally to a joint. One side of a metal plate will curl up toward the weld.
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9-12. Weld Test Vise Weld Joint Hammer Strike the weld joint in the direction shown. A good weld bends over but does not break. If the weld breaks, examine it to determine the cause. If the weld is porous (many holes), the arc length was probably too long.
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Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle.
SECTION 10 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2018-01 Whenever possible and practical, use DC weld output instead of AC weld output. 10-1. Selecting Tungsten Electrode ( Wear Clean Gloves To Prevent Contamination Of Tungsten A.
10-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information.
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Notes Welding Tip: Securely connect work clamp to a clean area close to the weld joint.
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See Drive Roll And Wire Guide Kits Hardware is common and not available unless listed. 956142881_18-A Figure 12-2. Wire Drive Assembly OM-253918 Page 68...
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Table 12-1. Drive Roll And Wire Guide Kits 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. V-Knurled rolls for hard shelled cored wires. 4.
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Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
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Effective January 1, 2018 (Equipment with a serial number preface of MJ 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 —...
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