Miller I-24A User manual

Processes
Description
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Wire Feeder
OM-186895AK 2017−07
I-24A
File: MIG (GMAW)
CE
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com

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 2017−06

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 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5...........................
2-1. Symboles utilisés 5.....................................................................
2-2. Dangers relatifs au soudage à l’arc 5......................................................
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7.....
2-4. Proposition californienne 65 Avertissements 8..............................................
2-5. Principales normes de sécurité 8.........................................................
2-6. Informations relatives aux CEM 8.........................................................
SECTION 3 − DEFINITIONS 9..................................................................
3-1. Additional Safety Symbols And Definitions 9................................................
3-2. Miscellaneous Symbols And Definitions 11..................................................
SECTION 4 − SPECIFICATIONS 12..............................................................
4-1. Serial Number And Rating Label Location 12................................................
4-2. Unit Specifications 12....................................................................
4-3. Wire Type, Size and Feed Speed Table 12..................................................
4-4. Environmental Specifications 12...........................................................
SECTION 5 − INSTALLATION 13................................................................
5-1. Selecting A Location 13..................................................................
5-2. Equipment Connection Diagrams 14.......................................................
5-3. 14-Pin Receptacle, Shielding Gas And Optional Volt Sense Lead 14.............................
5-4. 14-Pin Receptacle Information 15..........................................................
5-5. Connecting Welding Gun And Weld Cable 15................................................
5-6. Optional Meter Circuit Board Settings 16....................................................
5-7. Motor Start/Burnback Control 17...........................................................
5-8. Installing Wire Guide And Drive Roll 18.....................................................
5-9. Installing And Threading Welding Wire 19...................................................
SECTION 6 − OPERATION 20...................................................................
6-1. Front Panel Controls 20..................................................................
6-2. Optional Side Panel Controls 21...........................................................
SECTION 7 − MAINTENANCE & TROUBLESHOOTING 21.........................................
7-1. Routine Maintenance 21.................................................................
7-2. Overload Protection 22..................................................................
7-3. Troubleshooting 22......................................................................
SECTION 8 − ELECTRICAL DIAGRAM 23........................................................
SECTION 9 − PARTS LIST 24...................................................................
WARRANTY

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).
Product/Apparatus Identification:
Product Stock Number
I24A W/CE & EURO GUN CONNECTIONS 186493
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5:2013 Arc welding equipment – Part 5: Wire feeders
•IEC 6097410:2014 Arc welding equipment – Part 10: Electromagnetic compatibility requirements
Signatory:
_____________________________________ ___________________________________________
David A. Werba Date of Declaration
MANAGER,PRODUCT DESIGN COMPLIANCE
March 22, 2017
241323G

OM-186895 Page 1
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
7
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
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-
plainedin 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.
Touching live electrical parts can cause fatal shock
s
or severe burns. The electrode and work circuit i
s
electricallylive whenever the output is on. The inpu
t
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automati
c
wire welding, the wire, wire reel, drive roll housing
,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperl
y
groundedequipment is a hazard.
DDo not touch live electrical parts.
ELECTRIC SHOCK can kill.
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
thereis 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
locationsor 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-
ableor 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, ground, and operate 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
powercord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
DWhenmaking input connections, attach proper grounding conduc-
tor first − double-check connections.
DKeepcords dry, free of oil and grease, and protected from hot metal
and sparks.
DFrequently inspect input power cord and ground conductor for
damageor bare wiring – replace immediately if damaged – bare
wiring can kill.
DTurn off all equipment when not in use.
DDo not use worn, damaged, undersized, or repaired 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. Disconnect cable for process not in
use.
DUse GFCI protection when operating auxiliary equipment in damp
or wet locations.
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
beforetouching any parts.
HOT PARTS can burn.
DDo not touch hot parts bare handed.
DAllow cooling period before working on
equipment.
DTo handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.