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OM-229 038D 2007−04
Effective with serial number 226 214
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
Wire Feeder
Migmatic 221/253
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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. 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 bu
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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 Insta
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Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer: European Contact: ITW Welding Products Italy S.r.l. Mr. Danilo Fedolfi, Via Privata Iseo 6/E Managing Director 20098 San Giuliano ITW Welding Products Italy S.r.l. Milanese, Italy Via Privata Iseo 6/E Phone: 39(02)98290-1 20098 San Giuliano Milanese, Italy Phone: 39(02)98290-1 Fax: 39(02)98290203 European Contact Signature: D
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 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 Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessa
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching HOT PART
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Have only qualified persons remove doors, Do not overload building wiring − be sure power supply system is panels, covers, or guards for main
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American Nationa
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SECTION 2 − DEFINITIONS Warning! Watch Out! There are possible 2.1 Keep your head out of the fumes. 4 Arc rays can burn eyes and injure hazards as shown by the symbols. skin. 2.2 Use forced ventilation or local exhaust to remove the fumes. 1 Electric shock can kill. 4.1 Wear hat and safety glasses. Use 2.3 Use ventilating fan to remove fumes. 1.1 Wear dry insulating gloves. Do not ear protection and button shirt collar. touch electrode with bare hand. Do 3 Welding sparks can cause explosion Use
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Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Read the Owner’s Manual before working on this machine. 1 Consult rating label for input power requirements, and check power available at the job site − they must match. 2 Read Owner’s Manual and inside labels for connection points and procedures. 3 Move jumper links as shown on inside label to match voltage at job site. 4 Having a
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1 Warning! Watch Out! There 4 are possible hazards as 3 1 2 shown by the symbols. 2 Electrical shock from wiring can kill. 3 Read Owner’s Manual before working on this machine 4 Wear approved safety glasses 5 Electrode Positive (Straight Polarity) 6 Electrode Negative (reverse Poalrity) 6 5 2-1. WEEE Label Do not discard this product with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collec- tion facility. Contact your local recycli
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SECTION 3 − INSTALLATION 3-1. Specifications Rated Input Amperage Rated Input Amperage Max. Max. at Rated Output at Rated Output Rated Rated Output Output Open Open Dimension Dimension W Weight eight Circuit Circuit 100% 60% 20% 220/230 VAC 50Hz (mm) (kg) Model Voltage 90 A 116 A 210 A 32 A 221 41 480 x 800 x 1050 85 Net 18.5 V 20.0 V 24.0 V 3 A* Wire feed speed range 1.3 mpm to 20 mpm. * While idling Rated Input Amperage Rated Input Amperage Max. Max. Rated Output Rated Output at Rated Output a
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3-3. Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. Model 253 Model 221 MAX MIN 3-4. Installing Gas Supply Chain gas cylinder to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 Regulator/Flow Gauge Install so face is vertical. 2 Gas Hose Connection 3 Flow Adjust Typical flow rate is 0.9 liters p
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3-5. Installing Wire Spool and Adjusting Hub Tension Use compression spring with 200 mm (8 in) spools. When a slight force is needed to turn spool, tension is set. Tools Needed: 24 mm (15/16 in) 072573-B 3-6. Positoning Jumper Links (230/400V 3-Phase Models) 230 V 400 V OM-229 038 Page 10
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3-7. Electrical Service Guide Migmatic Model 221 253 220/230 230 400 Input Voltage 26 23 13 Input Amperes at Rated Output Max Recommended Standard Fuse or Circuit Breaker Rating in Amperes 26 23 13 2 ** Input Conductor Size in mm 4 4 4 2 ** Grounding Conductor Size in mm 4 4 4 ** Power cord supplied with the unit is sized for 230V operation. Larger power cord may be required for cable lengths greater than 3 meters. Consult national and local regulations. 3-8. Selecting a Location and Connecting
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B. 3-Phase Installation must meet all National and Local Codes − have only quali- fied persons make this installation. 3 Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Always connect green or green/ = GND/PE yellow conductor to supply Earth Ground grounding terminal first, and never to a line terminal. 4 For Three-Phase Operation 1 Input Power Cord. 2 Disconnect Device (switch shown in the OFF position) 7 3 Green Or Green/Yellow Grounding Condu
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3-9. Installing Drive Rolls and Wire Guide 1 Securing Screw 2 Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 3 Anti-Wear Guide Install guide as shown. 4 Drive Roll 3 The drive roll consists of two differ- 2 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. The groove closest to the motor shaft is the proper groove to thread. 1 Turn nut one click
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3-10. Threading Welding Wire and Adjusting Pressure Roll Tension 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable 4 Lay gun cable out straight. 7 1 Tools Needed: 2 6 3 5 Hold wire tightly to keep it from unraveling. 150 mm (6 in) Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. Use pressure indicator Tighten scale to set a desired drive roll pressure. 1
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3-11. Using Gun/Cable Holder 1 Consumable Storage Compartment Press latch down to release and open door. Provides storage space for gas nozzles, contact tips, gas diffusers. 1 3-12. Setting Gun Polarity for Wire Type (Optional) 1 Electrode Positive (DCEP) For solid steel, stainless steel, alu- minum, or flux core with gas, wires (GMAW). 2 Electrode Negative (DCEN) For gasless flux core wires 1 (FCAW), wire drive assembly be- comes negative. 2 221−253−4 / 221−253−5 OM-229 038 Page 15
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SECTION 4 − OPERATION 4-1. Controls for Migmatic 221/253 1 Power Switch 2 Voltage Control Turn control clockwise to increase voltage. 4 5 3 High Temperature Shutdown 3 Light (Orange LED) 4 Digital Display* 6 Volts/Amps/Wire Feed Speed with last value hold function. Trigger 2 mode (2T/4T) is shown at power on for 3 seconds and when Trigger mode is changed. 5 Power Indicator Light (White 1 LED) 6 Wire Feed Speed Control 7 Turn control clockwise to increase wire feed speed. This control also 8 cont
