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OM-181 931F
November 2001
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
S-22P12 Ultra-Lite
Visit our website at
www.MillerWelds.com
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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 Installation, Operation, and Maintenance . . . . . . .
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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’s Name: Miller Electric Mfg. Co. Manufacturer’s Address: 1635 W. Spencer Street Appleton, WI 54914 USA Declares that the product: S-22P12 Ultra-Lite conforms to the following Directives and Standards: Directives Low Voltage Directive: 73/23/EEC Electromagnetic Compatibility (EMC) Directive: 89/336/EEC Machinery Directives: 89/39
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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 necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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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 a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 li
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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. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- 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 resea
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Drive rolls can injure fingers Welding wire and drive parts are at welding voltage during operation – keep hands and metal objects clear. 1 Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1 1.1 1.2 1.3 1.2 Protect yourself from electric shock by insulating yourself from work and ground. 1.
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2-2. Manufacturer’s Rating Label For CE Products For label location see Section 3-7. S/N: U 24 V 1 50/60 Hz 1 = IP 23 I = 7 A 1 U 100 V I = 500 A X 100 % 2 2 = MILLER ELECTRIC MFG. CO., APPLETON, WI USA ST-178 794-A 2-3. Symbols And Definitions Some symbols are found only on CE products. NOTE Output Alternating Current Amperes Volts V A Degree Of Single Phase Wire Feed Hertz Hz IP Protection Cold Jog (Inch) To- Duty Cycle Purge By Gas Increase X wards Workpiece Conventional Load Read Instructio
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3-2. Equipment Connection Diagram 1 Constant Voltage (CV) Welding Power Source Supplying 24 VAC To Feeder Use optional PSA-2 adapter for power sources having only 115 1 VAC supply. 2 Negative (–) Weld Cable 3 Positive (+) Weld Cable 4 Workpiece 11 5 Interconnecting Cord (Customer Supplied) 6 14-Pin Plug And Cord 7 Wire Feeder 8 Gun 2 9 Gun Trigger Receptacle 10 Gas Hose 11 Gas Cylinder 3 10 5 9 4 6 8 7 Gun Recommendation Table Process Gun M25 Or M40 GMAW – Hard or Cored Wires FCAW – Self-Shieldi
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3-4. Connecting Shielding Gas And 14-Pin Plug 1 Gas Hose With 5/8-18 Right-hand Thread Fittings (Customer Supplied) 4 2 Shielding Gas Cylinder 3 Valve 4 Flowmeter 3 Close valve on cylinder when fin- ished welding. 5 14-Pin Plug 2 1 Tools Needed: 5 5/8 in Ref. ST-801 155-A / Ref. ST-801 131 3-5. 14-Pin Plug Information Pin* Pin Information A 24 volts ac with respect to socket G. B Contact closure to A completes 24 volts ac contactor control circuit. J J A A K I B G Circuit common for 24 volts AC
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3-7. Connecting Weld Cable And Installing Drive Rolls 2 1 Weld Cable From Welding Power Source Route weld cable from power source through rear panel and con- nect to terminal on drive assembly. Install and secure wire guide. Install drive rolls and turn drive roll nut one click. Only drive gear is adjustable. Turn adjustment screw in or out until groove in drive roll lines up with wire guide as shown. Remove drive rolls, and clean grooves using a wire brush. 2 Rating Label Location Installation
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3-8. Installing And Threading Welding Wire Install wire spool. Adjust tension screw so wire is taut when wire feed stops. Lay gun cable out straight. Open pressure assembly, hold wire tightly, and cut off end. Push wire through guides into gun. Close and tighten pressure assem- bly. Press JOG button until wire comes out gun. To adjust drive roll pressure, press gun trigger to feed wire against wood surface. Tighten knob so wire does not slip. Cut off wire. Close door. Tighten WOOD Tools Needed:
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SECTION 4 – OPERATION 4-1. Controls 1 Wire Speed Meter (Optional) 2 Voltage Meter (Optional) 3 Power Control Switch 1 2 4 Jog/Purge Switch Push up to momentarily feed welding wire at speed set on Wire 3 Speed control without energizing 5 welding circuit or shielding gas valve. Push down to momentarily ener- gize gas valve to purge air from gun or adjust gas regulator. 4 5 Wire Speed Control ST-139 026-B SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Disconnect power Main
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5-2. Overload Protection 1 Turn Off wire feeder and welding power source. Stop engine on welding generator. 1 Circuit Breaker CB1 2 Fuse F1 CB1 and F1 protect wire feeder from overload. Correct problem and reset CB1 or replace F1. Close and latch door. 2 Ref. 800 586-B / Ref. 801 128-B 5-3. Troubleshooting Table Trouble Remedy Wire does not feed, unit completely inop- Turn Power switch On. erative. Check fuse F1 and replace if necessary (see Section 5-2). Check 14–pin plug PLG2 connections. Ch
