Miller Migmatic 220 DX User manual

MigMatic 220DX/250DX
Spool Gun
CE
Processes
Description
R
MIG (GMAW) Welding
Feeder Gun
OM-250 884A 2011−01
Visit our website at
www.MillerWelds.com
File: MIG (GMAW)

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 specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
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. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
−every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Mil_Thank 2009−09

TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS - READ BEFORE USING 1.................................
1-1. Symbol Usage 1.......................................................................
1-2. Arc Welding Hazards 1.................................................................
1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................
1-4. California Proposition 65 Warnings 4......................................................
1-5. Principal Safety Standards 4.............................................................
1-6. EMF Information 4.....................................................................
SECTION 3 −INSTALLATION 5................................................................
3-1. Important Information Regarding CE Products (Sold Within The EU) 5..........................
3-2. Specifications 5........................................................................
3-3. Connecting Spool Gun To MigMatic 220DX/250DX 6.........................................
3-4. Opening Cover 7......................................................................
3-5. Installing Wire Spool And Threading Welding Wire 8.........................................
3-6. Adjusting Drive Roll And Spool Brake Pressure 9...........................................
3-7. Adjusting Position Of Spool Canister 10.....................................................
SECTION 4 −OPERATION 11...................................................................
4-1. Controls 11............................................................................
4-2. Shielding Gas 11........................................................................
SECTION 5 −MAINTENANCE & TROUBLESHOOTING 12.........................................
5-1. Routine Maintenance 12.................................................................
5-2. Changing Gun Contact Tip 12.............................................................
5-3. Replacing Inlet Guide 13.................................................................
5-4. Gun Drive Assembly Maintenance 14......................................................
5-5. Troubleshooting 14......................................................................
SECTION 6 −ELECTRICAL DIAGRAM 15........................................................
SECTION 6 −PARTS LIST 16...................................................................
WARRANTY

DECLARATION OF CONFORMITY
for European Community (CE marked) products.
ITW Welding Products Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy 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).
Product/Apparatus Identification:
Product Stock Number
MigMatic 220DX/250DX SPOOL GUN W/EURO+BZ 058020018
MigMatic 220DX/250DX SPOOL GUN W/EURO PLASTIC BOX 058020019
Council Directives:
•2006/95/EC Low Voltage
Standards:
•IEC 609741 Arc Welding Equipment  Welding Power Sources: edition 3, 200507.
•IEC 609747 Arc Welding Equipment  Torches: edition 2, 200507.
•EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding, arc
welding and allied processes with the basic restrictions related to human exposure to electromagnetic fields
(0Hz300Hz)
EU Signatory:
December 17th, 2010
___________________________________________________________________________________
Massimigliano Lavarini Date of Declaration
ELECTRONIC ENGINEER R&D TECH.SUPPORT
956 142 843

OM-250 884 Page 1
SECTION 1 −SAFETY PRECAUTIONS - READ BEFORE USING
som _2010−03
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! −Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
NOTICE −Indicates statements not related to personal injury.
.Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
DDo not touch live electrical parts.
DWear dry, hole-free insulating gloves and body protection.
DInsulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
DDo not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
DUse AC output ONLY if required for the welding process.
DIf AC output is required, use remote output control if present on
unit.
DAdditionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomaticDC 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!
DDisconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
DProperly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
DAlways verify the supply ground −check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
DWhen making input connections, attach proper grounding conduc-
tor first −double-check connections.
DKeep cords dry, free of oil and grease, and protected from hot metal
and sparks.
DFrequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged −bare wiring can kill.
DTurn off all equipment when not in use.
DDo not use worn, damaged, undersized, or poorly spliced cables.
DDo not drape cables over your body.
DIf earth grounding of the workpiece is required, ground it directly
with a separate cable.
DDo not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
DDo not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
DUse only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
DWear a safety harness if working above floor level.
DKeep all panels and covers securely in place.
DClamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
DInsulate work clamp when not connected to workpiece to prevent
contact with any metal object.
DDo not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing power sources AFTER removal of input power.
DTurn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
DDo not touch hot parts bare handed.
DAllow cooling period before working on equip-
ment.
DTo handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.

OM-250 884 Page 2
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
DKeep your head out of the fumes. Do not breathe the fumes.
DIf inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
DIf ventilation is poor, wear an approved air-supplied respirator.
DRead and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
DWork in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
DDo not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
DDo not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
DWear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
DWear approved safety glasses with side shields under your
helmet.
DUse protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
DWear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
ARC RAYS can burn eyes and skin.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
WELDING can cause fire or explosion.
DRemove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
DDo not weld where flying sparks can strike flammable material.
DProtect yourself and others from flying sparks and hot metal.
DBe alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
DWatch for fire, and keep a fire extinguisher nearby.
DBe aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
DDo not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
DDo not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
DConnect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
DDo not use welder to thaw frozen pipes.
DRemove stick electrode from holder or cut off welding wire at
contact tip when not in use.
DWear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
DRemove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
DAfter completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
DUse only correct fuses or circuit breakers. Do not oversize or by-
pass them.
DFollow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
DWelding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
DWear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
DShut off shielding gas supply when not in use.
DAlways ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF
)
can affect Implanted Medical Devices.
DWearers of Pacemakers and other Implanted
Medical Devices should keep away.
DImplantedMedical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
DWear approved ear protection if noise level is
high.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
CYLINDERS can explode if damaged.
DProtect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
DInstall cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
DKeep cylinders away from any welding or other electrical circuits.
DNever drape a welding torch over a gas cylinder.
DNever allow a welding electrode to touch any cylinder.
DNever weld on a pressurized cylinder −explosion will result.
DUse only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
DTurn face away from valve outlet when opening cylinder valve.
DKeep protective cap in place over valve except when cylinder is in
use or connected for use.
DUse the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
DRead and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

OM-250 884 Page 3
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
DDo not install or place unit on, over, or near
combustible surfaces.
DDo not install unit near flammables.
DDo not overload building wiring −be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
DUse lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
DUse equipment of adequate capacity to lift and
support unit.
DIf using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
DKeep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
DFollow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
DAllow cooling period; follow rated duty cycle.
DReduce current or reduce duty cycle before
starting to weld again.
DDo not block or filter airflow to unit.
FLYING SPARKS can injure.
DWear a face shield to protect eyes and face.
DShape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
DSparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
DPut on grounded wrist strap BEFORE handling
boards or parts.
DUse proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can injure.
DKeep away from moving parts.
DKeep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
DDo not press gun trigger until instructed to do
so.
DDo not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
MOVING PARTS can injure.
DKeep away from moving parts such as fans.
DKeep all doors, panels, covers, and guards
closed and securely in place.
DHave only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
DReinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
DRead and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
DUse only genuine replacement parts from the manufacturer.
DPerform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
H.F. RADIATION can cause interference.
DHigh-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
DHave only qualified persons familiar with
electronic equipment perform this installation.
DThe user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
DIf notified by the FCC about interference, stop using the
equipmentat once.
DHave the installation regularly checked and maintained.
DKeep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
DElectromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
DBe sure all equipment in the welding area is
electromagneticallycompatible.
DTo reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
DLocate welding operation 100 meters from any sensitive elec-
tronic equipment.
DBe sure this welding machine is installed and grounded
according to this manual.
DIf interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

OM-250 884 Page 4
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc-
tive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: [phone], website:
www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: [phone], website:
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: [phone], website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727,website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: [phone], web-
site: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: [phone], website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: [phone], website:
www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The Na-
tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may inter-
fere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or individual risk assess-
ment for welders. All welders should use the following procedures in
order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
ImplantedMedical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.

OM-250 884 Page 5
SECTION 2 −INSTALLATION
2-1. 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.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
SThe EMF assessment on this equipment was conducted at 0.5 meter.
SAt a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
2-2. Specifications
Wire Diameter Range Approximate
Wire Feed
Range
Cooling
Method Maximum Spool Size Weld Circuit Rating Overall Dimensions Weight
0.8 Thru 1.0 mm
(.030 Thru .039 in.)
Aluminum Wire
0.8 Thru 1.0 mm
(.023 Thru 039 in.)
Solid Or Cored Wire
1 To 22 mpm
(39.4 To 866 ipm) Air Cooled 100 mm (4 in.) Diameter
190 Amperes,
60% Duty
Cycle Using
CO2
160 Amperes,
60% Duty
Cycle Using
MIX
Length:
410 mm (16.14 in.)
Width:
100 mm (3.94 in.)
Height:
290 mm (11.4 in.)
4.8 kg (10.6 lb)
Gun With Cable
.Use welding power source Owner’s Manual during gun installation. If contact tip, liner, and drive roll groove are not correct for wire size and type,
see Section 4 to change parts as needed. See Parts List for other available contact tips.
Notes

OM-250 884 Page 6
2-3. Connecting Spool Gun To MigMatic 220DX/250DX
Ref 956142722_2-12_A
.See the MigMatic 220DX/250DX
Owner’s Manual for additional in-
formation on connecting and op-
erating the spool gun.
.The spool gun works only with the
welding power source in the
Manual mode and Wire feed
speed is controlled by the spool
gun Wire Speed control (see Sec-
tion 3-1).
If the welding power source is in
the Synergic mode, the spool gun
works only with Aluminum wire.
.There is no weld output and the
welding power source Digital Dis-
play Meter displays three dashes
(_ _ _) if weld parameters (wire
diameter and type) are incorrect.
1 Spool Gun Mode LED
The Spool Gun Mode LED lights and
the 2T and 4T trigger modes are dis-
abled when a spool gun is connected
to the 7−pin receptacle.
2 Spool Gun 7-Pin Receptacle
3 Spool Gun 7-Pin Plug
Insert plug into receptacle and tighten
threaded collar. The Spool Gun Mode
LED lights.
4 MIG Torch Receptacle
5 MIG Torch Plug
Insert plug into receptacle and tighten
threaded collar.
6 Regulator/Flowmeter
Route shielding gas hose up to regulat-
or/flowmeter. Connect gas hose to
fitting on regulator/flowmeter. Insert oth-
er end of gas hose into gas valve con-
nector.
Tools Needed:
3/4, 5/8 in.
6
1
3
2
45

OM-250 884 Page 7
2-4. Opening Cover
Ref. 956142722_3-12_A
1 Thumbscrew
2 Cover
Loosen thumbscrew and rotate
cover open.
1
2
Notes

OM-250 884 Page 8
2-5. Installing Wire Spool And Threading Welding Wire
Ref. 956142722_4-12_A
1 Cover
2 Canister
3 Thumbscrew (Cover)
Loosen thumbscrew and remvoe
cover.
4 Wire Spool
Loosen wire from spool, cut off bent
wire, and pull 6 in. (150 mm) of wire
off spool.
5 Pressure Roll Assembly
Press arm inward to open pressure
roll assembly.
6 Wire Inlet Guide
7 Drive Roll Groove
8 Contact Tip
Thread wire through wire inlet
guide, along drive roll groove, and
out contact tip.
Install spool so wire feeds off bot-
tom. See Section 2-7 for informa-
tion on adjusting spool position.
9 Spool Brake Thumbnut
If necessary, turn thumbnut
counterclockwise slightly to install
spool.
Close cover and secure with
thumbscrew.
Tools Needed:
6
7
1
2
3
4
5
8
9

OM-250 884 Page 9
2-6. Adjusting Drive Roll And Spool Brake Pressure
Ref. 956142722_5-12_A
1 Cover
2 Thumbscrew
Loosen thumbscrew and rotate
cover open.
3 Spool
Cut welding wire off at contact tip.
Retract wire onto spool and secure
wire.
4 Spool Brake Thumbnut
Grasp spool in one hand and turn
spool while adjusting spool brake
thumbnut. When a slight force is
neededto turn spool, tension is set.
Do not overtighten.
Thread welding wire (see Section
2-5).
5 Drive Roll Tension Thumbnut
Turn On unit and check drive roll
pressure by feeding wire against a
wood board or concrete surface;
wire should feed steadily without
slipping.
Adjust drive roll tension thumbnut if
necessary. Do not overtighten.
!Turn off welding power
source.
Close cover.
Tools Needed: WOOD
Adjusting Pressure
1
4
2
3
5

OM-250 884 Page 10
2-7. Adjusting Position Of Spool Canister
Ref. 956142722_6-12_A
The canister can be moved to three
positions.
Before welding, move the spool
canister to the position that allows
the gun to be handled most comfort-
ably.
1 Canister Adjustment Screw
Loosen screw and move spool can-
ister to the desired position. Tight-
en screw.
Tools Needed:
1
Spool Wire Position
Spool Wire Position
1
Note position of canister.
Note position of canister.

OM-250 884 Page 11
SECTION 3 −OPERATION
3-1. Controls
1 Trigger
Press trigger to energize welding
power source contactor (if applica-
ble), start shielding gas flow, and be-
gin wire feed.
For shielding gas preflow and post-
flow, lightly press trigger before and
after welding.
2 Wire Speed Control
Use control to adjust wire feed speed.
Rotate control clockwise to increase
wire feed speed.
.See the MigMatic 220DX/250DX
Owner’s Manual for additional
information on connecting and
operatingthe spool gun.
.The spool gun works only with
the welding power source in the
Manual mode.
If the welding power source is in
the Synergic mode, the spool
gun works only with Aluminum
wire.
.There is no weld output and the
welding power source Digital
Display Meter displays three
dashes (_ _ _) if weld parameters
(wire diameter and type) are in-
correct.
1
Ref. 956142722_7-12_A
2
3-2. Shielding Gas
sb5.1* 6/92 −S-0621-C / Ref. 956142722_7-12_A
1 Shielding Gas Cylinder
2 Valve
3 Gun Trigger
Open valve on cylinder just before
welding.
Gun trigger turns weld output and
gas flow on and off. For shielding
gas preflow and postflow, lightly
press trigger before and after
welding.
Close valve on cylinder when fin-
ished welding.
1
2
3

OM-250 884 Page 12
SECTION 4 −MAINTENANCE & TROUBLESHOOTING
4-1. Routine Maintenance
!Disconnect power
before maintaining.
.Maintain more often
during severe conditions.
3 Months
Replace
Damaged Or
Unreadable
Labels
Replace
Damage
Gas Hose
Clean
And
Tighten
Weld
Terminals
Repair Or Replace
Cracked Cables
And Cords
6 Months
Blow Out Or
Vacuum Inside Clean
Drive
Rolls
4-2. Changing Gun Contact Tip
!Turn off welding power source.
1 Nozzle
2 Contact Tip
3 Tension Spring
Remove nozzle
Unscrew contact tip.
Install new contact tip.
Reinstall nozzle. The tension spring
allows the nozzle to be connected to
the shaft.
Tools Needed:
Ref. 956142722_9-12_A
1
2
3

OM-250 884 Page 13
4-3. Replacing Inlet Guide
!Turn off welding power
source.
1 Pressure Roll Assembly
Cut off welding wire where it enters
pressure roll assembly area.
2 Nozzle
Pull wire out nozzle end.
3 Thumbscrew
4 Cover
Loosen thumbscrew and remove
cover.
5 Wire Spool
6 Spool Brake Thumbnut
Loosen thumbnut, retract wire onto
spool, secure wire, and remove
spool.
7 Inlet Guide
Use pliers to remove inlet guide.
Install new guide.
Reinstall spool and thread welding
wire (see Section 2-5).
Adjust spool brake pressure and
drive roll pressure if necessary (see
Section 2-6).
Reinstall cover.
Tools Needed:
Ref. 956142722_10-12_A
1
2
3
4
5
6
7

OM-250 884 Page 14
4-4. Gun Drive Assembly Maintenance
Ref. 956142722_11-12_B
!Turn off welding power
source.
Retract wire onto spool.
1 Drive Roll Cap
Rotate drive roller cap counter-
clockwise and remove it from the
drive roller.
2 Drive Roll
Loosen set screw and remove drive
roll.
Use wire brush to clean drive roll.
Install drive roll with desired groove
down; rotate drive roll so set screw
faces flat side of shaft. Tighten set
screw.
3 Pressure Roll Assembly
4 Bearing
Open pressure roll assembly to ac-
cess bearing. Use proper brush to
clean bearing.
Thread welding wire through gun
(see Section 2-5). Adjust drive roll
pressure, if necessary (see Section
2-6). Close and secure cover.
Tools Needed:
1
2
34
4-5. Troubleshooting
Trouble Remedy
No weld output; gun/feeder does not
work.
Place Power switch on welding power source in the On position (see welding power source Owner’s
Manual).
Erratic weld output. Tighten and clean all connections.
Wire feeds, shielding gas flows, but
welding wire is not energized.
See Troubleshooting section in welding power source Owner’s Manual.
Wire feeds erratically. Check and correct drive roll pressure (see Section 2-6).
Clean drive roll or replace drive roll (see Section 4-4).
Decrease spool brake pressure (see Section 2-6).

OM-243 762 Page 15
SECTION 5 −ELECTRICAL DIAGRAM
956142723-A
Figure 6-1. Circuit Diagram For Gun/Feeder

OM-250 884 Page 16
SECTION 6 −PARTS LIST
956142722_12-12_A
1
2
3
4
5
6
7
89
10 11
12
13 14 15 16
17
18
19
20
21
22
24
26
23
24
24
25
26
27
28
29
30
31 32 33
26 26
14
34 35
36
37
38
25
25
25
26
39
.Hardware is common and
not available unless listed.
Figure 7-1. Complete Assembly