Miller 22A User manual

Miller
The
Power
efBlue.
OM180
805D
August
1998
Processes
~
MIG
(GMAW)
Welding
Flux
Cored
(FCAW)
Welding
Description
Wire Feeder
22A
&
24A
OWNERS
MANUAL

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.
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.
ISO
9001
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
which
exact
part
you
may
need
to
fix the
problem.
Warranty
and
service
information
for
your
particular
model
are
also
provided.
IH~UIST~H~L~
I
QUALITY
SYSTEM
Miller is
the first
weldilu eiulp.elt
manuf.cturer
I.
the U.S.A.
tu
~e
registered
tu
the
ISO
0001
quullty
System
Standard.
r
~I8
.
oI_
t.~
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
catalog
sheets.
To
locate
your
nearest
distributor
call
1-800-4-A-Miller.

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.
Principal Safety
Standards
3
1-5. EMF Information
4
SECTION
1
-
CONSIGNES
DE SECURITE
-
LIRE
AVANT
UTILISATION
5
1-1.
Signification
des
symboles
5
1-2.
Dangers
relatifs
au
soudage
a
Iarc
5
1-3.
Dangers
supplØmentaires
en
relation
avec
linstallation,
le
fonctionnement
et
Ia
maintenance
7
1-4.
Principales
normes
de
sØcuritØ
8
1-5.
Information
sur
les
champs
electromagnetiques
8
SECTION
2
-
DEFINITIONS
9
2-1.
Warning
Label
Definitions
9
2-2.
Rating
Label
For CE
Products 10
2-3.
Symbols
And
Definitions
10
SECTION
3-
INSTALLATION
11
3-1.
Specifications
11
3-2.
Site Selection
11
3-3. Gun
Recommendation Table
12
3-4.
Equipment
Connection
Diagrams
12
3-5.
14-Pin
Receptacle,
Shielding
Gas And
Optional
Volt
Sense
Lead
12
3-6.
14-Pin
Receptacle
Information
13
3-7.
Connecting
Welding
Gun And
Weld
Cable
13
3-8.
Optional
Meter
Circuit
Board
Seth
ngs
14
3-9.
Motor
Start/Burnback
Control
15
3-1
0.lnstalling
Wire
Guide
And Drive
Roll
16
3-11.lnstalling
And
Threading Welding
Wire
17
SECTION
4
-
OPERATION
18
4-1. Front Panel
Controls
18
4-2.
Optional
Side
Panel
Controls
19
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
19
5-1.
Routine Maintenance
19
5-2.
Overload
Protection
20
5-3.
Troubleshooting
20
SECTION
6-
ELECTRICAL
DIAGRAM
22
SECTION
7
-
PARTS
LIST
.23
OPTIONS
AND
ACCESSORIES
WARRANTY
OM-186 895D

Declaration
of
Conformity
for
European
Community
(CE)
Products
NOTE
iri~
This in
formation
is
provided
for
units
with CE
certification
(see
rating
label
on
unit).
Manufacturers
Name:
Miller
Electric
Mfg.
Co.
Manufacturers Address:
1635
W.
Spencer
Street
Appleton,
WI
54914
USA
Declares that
the
product:
22P~
aO~fl
d
24P~
con
forms
to
the
following
Directives
and Standards:
Directives
Low
Voltage
Directive:
73/23/EEC
Electromagnetic
Compatibility
(EMC)
Directive:
89/336/EEC
Machinery
Directives:
89/392/EEC,
91/368/EEC,
93/C
133/04,
93/68/EEC
Standards
Arc
Welding
Equipment
Part I:
Welding
Power
Sources:
IEC
974-1
(April
1995
-
Draft
Revision)
Arc
Welding
Equipment:
Wirefeed
Systems:
lEO
974-4
(May
1995
-
Draft
Revision)
Degrees
of Protection Provided
By
Enclosures
(IP
Code):
IEC
529:1989
Insulation
Coordination
For
Equipment
With
Low-Voltage
Systems:
Part I:
Principles, Requirements
and Tests:
IEC
664-1:
1992
Electromagnetic
Compatibility,
(EMC):
EN
50199
European
Contact:
Mr.
Luigi
Vacchini,
Managing
Director
MILLER
Europe
S.P.A.
Via Privata
Iseo
20098
San Giuliano
Milanese,
Italy
Telephone:
39(02)98290-1
Fax:
39(02)98281-552
dec_coni
1/96

SECTION 1
-
SAFETY
PRECAUTIONS
-
READ BEFORE
USING
som
_nd_5/97
~
~.i
.
~1~r~
~
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
ELECTRIC
SHOCK,
MOVING
PARTS,
and
HOT
PARTS
hazards.
Consult
symbols
and related
instructions
below for
necessary
actions
to
avoid
the hazards.
A
The
symbols
shown
below
are
used
throughout
this manual
to
call
attention
to
and
identity possible
hazards.
When
you
see
the
symbol,
watch
out,
and
tollowthe
related
Instructions
to
avoid the hazard. The
safety
information
given
beiow
is
only
a
summary
of the
more
complete
safety
Information
found
in the
Safety
Standards
listed
In Section
1-4. Read
and
follow
all
Safety
Standards.
A
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
A During
operation,
keep
everybody, especiaiiy
children,
away.
~
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.

Do
not
touch live
electrical
parts.

Wear
dry,
hole-free
insulating gloves
and
body
protection.

insulate
yourself
from
work
and
ground
using dry insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with the
work
or
ground.

Do
not
use
AC
output
in
damp
areas,
if
movement
is
confined,
or
if
there is
a
danger
of
falling.

Use
AC
output
ONLY if
required
for
the
welding
process.

if AC
output
is required,
use
remote
output
control
if
present
on
unit.

Disconnect
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).

Properly
install and
ground
this
equipment according
to
its
Owners
Manual
and
national,
state,
and local codes.

Always
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.

When
making input
connections,
attach
proper
grounding
conductor
first
-
double-check connections.

Frequently
inspect input
power
cord
for
damage
or
bare
wiring
-
replace
cord
immediately
if
damaged
-
bare
wiring
can
kill.

Turn
off
all
equipment
when
not
in
use.

Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.

Do
not
drape
cables
over
your
body.

If earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable
-
do
not
use
work
clamp
or
work cable.

Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another electrode from
a
different machine.

Use
only
well-maintained
equipment. Repair
or
replace damaged
parts
at
once.
Maintaln
unit
according
to
manual.

Wear
a
safety
harness
if
working
above
floor
level.

Keep
all
panels
and
covers
securely
in
place.

Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
worktable
as near
the
weld
as
practical.

Insulate
work
clamp
when
not
connected
to
workplece
to
prevent
contact
with
any
metal
object.

Do
not
connect
more
than
one
electrode
or
work cable
to
any
single
weld
output
terminal.
SIGNIFICANT DC VOLTAGE
exists
after
removal of
Input
power
on
inverters.

Turn
Off
inverter,
disconnect
input
power,
and
discharge input
capacitors according
to
instructions in Maintenance
Section
before
touching
any
parts.
Welding
produces
fumes and
gases.
Breathing
9.
these
fumes
and
gases
can
be
hazardous
to
your
health.

Keep
your
head
out
of the
fumes.
Do
not
breathe
the
fumes.

If
inside,
ventilate the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.

If
ventilation
is
poor,
use an
approved
air-supplied
respirator.

Read the
Material
Safety
Data Sheets
(MSDSs)
and the
manufacturers instructions for
metals,
consumables,
coatings,
cleaners,
and
degreasers.

Work 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
alr and
lower the
oxygen
level
causing injury
or
death.
Be
sure
the
breathing
air
is
safe.

Do
not
weld
in
locations
near
degreasing, cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic and
irritating
gases.

Do
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
if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these
elements
can
give
off toxic
fumes if
welded.
a
A
Marks
a
special
safety
message.
~
Means
Note~
not
safety
related.
i4..~Ar~W?lding.Hazards
~
~
..
.......~
..
...~
..~
~
OM-186
895
Page
1

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.

Wear
awelding
helmetfitted with
a
propershade
of filterto
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI Z49.1
and
Z87.1
listed
in
Safety
Standards).

Wear
approved
safety
glasses
with side shields under
your
helmet.

Use
protective
screens
or
barriers
to
protect
others
from
flash and
glare;
warn
others
not to
watch
the
arc.

Wear
protective
clothing
made
from
durable,
flame-resistant
material
(leather
and
wool)
and
foot
protection.
~
WELDING
can
causeflreorexploslon
Welding
on
closed
containers,
such
as
tanks,
drums,
orpipes,
cancausethemtoblowup.
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.

Protect
yourself
and others from
flying
sparks
and hot
metal.

Do
not
weld where
flying
sparks
can
strike
flammable
material.

Remove
all flammables within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible, tightly
cover
them with
approved
covers.

Be alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small cracks and
openings
to
adjacent
areas.

Watch
for
fire,
and
keep
a
fire
extinguisher nearby.

Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.

Do
not
weld
on
closed
containers
such
as
tanks,
drums,
or
pipes,
unless
they
are
properly
prepared according
to
AWS F4.1
(see
Safety
Standards).

Connect
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
and
fire
hazards.

Do
not
use
welder
to
thaw frozen
pipes.

Remove stick electrode from holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.

Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.

Remove
any
combustibles,
such
as a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
FLYING METAL
can
Injure
eyes

Welding, chipping,
wirebrushing,
and
g~nding
cause
sparks
and
flying
metal. As
welds
cool,
they
can
throw
off
slag.

Wear
approved
safety
glasses
with
side
shields
even
under
your
welding
helmet.
HOT
PAR1~S
can
cause
severe
burns
.
~
.
.
~
~

Do
not touch
hot
parts
bare
handed.

Allow
cooling
period
before
working
on
gun
or
torch.
~NO~E
can
damage
hear~ng~
..~
Noise
from
some
processes
or
equipment
can
damage
hearing.

Wear
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.

Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.

Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
failing
or
tipping.

Keep cylinders
away
from
any
welding
or
other
electrical
circuits.

Never
drape
a
welding
torch
over
a
gas
cylinder.

Never
allow
a
welding
electrode
to
touch
any
cylinder.

Never weld
on a
pressurized
cylinder
-
explosion
will result.

Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings designed
for
the
specific application;
maintain
them
and
associated
parts
in
good
condition.

Turn
face
away
from valve
outlet
when
opening cylinder
valve.

Keep protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.

Read
and
follow instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
skin

Shut off
shielding
gas
supply
when
not
in
use.

Always
ventilate confined
spaces
or use
approved
air-supplied respirator.
A

Pacemaker
wearers
keep
away.

Wearers should
consult
their doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
C
OM-186
895
Page
2

l-3,~
~d~jfloxIaISymbo~s
Fo~nstaflation,
Operation,
Ant~Ma~ntenance~\~
I

Do
not
install
or
place
unit
on,
over,
or
near
combustible
surfaces.

Do
not
install
unit
near
flammables.

Do
not
overload
building
wiring
-
be
sure
power
supply
system
is
properly
sized, rated,
and
protected
to
handle
this unit.
~AE\OR
EXPLOSION
hazard
JNG
UNIT\can
cause
inJury~
~,,
Use
lifting
eye
to
lift unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
Use
equipment
of
adequate
capacity
to
lift and
support
unit.

If
using
lift
forks
to
move
unit,
be
sure
forks
are
long
enough
to
extend
beyond
opposite
side of
unit.
H~F
RADIATION
can
cause
Interference

High-frequency
(HF)
can
interfere
with radio
navigation,
safety
services,
computers,
and
communications
equipment.

Have
only
qualified
persons
familiar
with
electronic
equipment perform
this
installation.

The
user
is
responsible
for
having
a
qualified
electrician
promptly
correct
any
interference
problem
resulting
from the
installation.

If
notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.

Have
the
installation
regularly
checked
and
maintained.

Keep
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.
~
-
-
-
~

Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.

Use
proper
static-proof
bags
and
boxes
to
store,
move,
or
ship
PC boards.
flNG
PARTS
can
cause
Injur~
-
:.aa.~,,:

Keep
away
from
moving
parts.

Keep
away
from
pinch
points
such
as
drive
rolls.
~ca.U
90
hijury
-
-
~
~
-
-
...~,,,....
~

Do
not
press
gun
trigger
until
instructed
to
do
so.

Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.

Be
sure
all
equipment
in the
welding
area
is
electromagnetically compatible.

To
reduce
possible
interference,
keep
weld
cables
as
short
as
possible,
close
together,
and down
low,
such
as
on
the floor.

Locate
welding
operation
100
meters
from
any
sensitive elec
tronic
equipment.

Be
sure
this
welding
machine is installed and
grounded
according
to
this
manual.

If
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.
Safety
in
Welding
and
Cutting,
ANSI Standard Z49.
1,
from American
Welding
Society,
550
N.W. LeJeune
Rd,
Miami FL 33126
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superinten
dent of
Documents, U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That Have Held Hazardous
Substances,
American
Welding
Society
Standard AWS
F4.1,
from American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
Code for
Safety
in
Welding
and
Cutting,
CSA Standard Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe Practices
For
Occupation
And
Educational
Eye
And Face
Protection,
ANSI Standard
Z87.i,from
American
National Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Nc.
PARTS,
can
~

Keep
away
from
moving
parts
such
as
fans.

Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.


Allow
cooling period;
follow rated
duty cycle.
Reduce
current
or
reduce
duty cycle
before
starting
to
weld
again.

Do
not
block
or
filter airflow
to unit.

Electromagnetic
energy
can
interfere
with
sensitive
electronic
equipment
such
as
computers
and
computer-driven
equipment
such
as
robots.
-
-~
~
.:
-
-
-
-
~
-
-
~
-
-
-
tl-4.
Pnnc~i
Safety
Standard~
OM-186
895
Page
3

EM~:i~~~ ~
~
T
~
~
Considerations
About
Welding
And The
Effects Of Low
Frequency
1.
Keep
cables close
together by twisting
or
taping
them.
Electric And
Magnetic
Fields
Welding
current,
as
it
flows
through welding
cables,
will
cause
electro-
2.
Arrange
cables
to
one
side
and
away
from the
operator.
magnetic
fields.
There
has
been
and still is
some concern
about
such
fields.
However,
after
examining
more
than 500 studies
spanning
17
3.
Do
not
coil
or
drape
cables around
your
body.
years
of
research,
a
special
blue ribbon
committee
of the
National
Research
Council
concluded that: The
body
of
evidence,
in
the
4.
Keep
welding
power
source
and
cables
as
far
away
from
opera-
committees
judgment,
has
not
demonstrated
that
exposure
to
power-
tor
as
practical.
frequency
electric
and
magnetic
fields
is
a
human-health hazard.
However,
studies
are
still
going
forth
and evidence
continues
to
be
5.
Connect
work
clamp
to
workpiece
as
close
to
the weld
as
examined. Until
the
final
conclusions
of the research
are
reached,
you
possible.
may
wish
to
minimize
your
exposure
to
electromagnetic
fields
when
welding
or
cutting.
About
Pacemakers:
To reduce
magnetic
fields
in
the
workplace,
use
the
following
Pacemaker
wearers
consult
your
doctorfirst.
If
cleared
by yourdoctor,
procedures:
then
following
the above
procedures
is
recommended.
OM-186 895
Page
4