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Manual Miller Electric 22A

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  • Miller Electric 22A - page 1

    Processes Description MIG (GMAW) W elding Flux Cored (FCA W ) W elding Wire Feeder OM-193 472N 2006 − 05 22A, 24A V isit our website at www.MillerWelds.com File: MIG (GMA W) ...

  • Miller Electric 22A - page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille ...

  • Miller Electric 22A - page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . ...

  • Miller Electric 22A - page 4

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  • Miller Electric 22A - page 5

    OM-193 472 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown i n the adjoining symbols. Y Marks a special safety m ...

  • Miller Electric 22A - page 6

    OM-193 472 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching ...

  • Miller Electric 22A - page 7

    OM-193 472 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. ...

  • Miller Electric 22A - page 8

    OM-193 472 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American W elding Society Standard A ...

  • Miller Electric 22A - page 9

    OM-193 472 Pa ge 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les util isés Sy mbole graphique d’avert iss ement ! Att ention ! Cette pro - cédur e comporte d es risques poss ibl ...

  • Miller Electric 22A - page 10

    OM-193 472 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la pe ...

  • Miller Electric 22A - page 11

    OM-193 472 Pa ge 7 2-3 . Dange rs suppléme ntaire s en r e lation avec l’installa tion, le f onc tionneme nt e t l a maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharge ...

  • Miller Electric 22A - page 12

    OM-193 472 Page 8 2-5. Princi pales nor mes de sécur ité Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W el ...

  • Miller Electric 22A - page 13

    OM-193 472 Page 9 SECTION 3 − INST ALLA TION 3-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating Overall Dimensions W eight 24 V olts AC Single Phase 7 Amperes 50/60 Hz Constant V oltage (CV) DC With 14-Pin And Contactor Control 75 to 750 ipm (1.9 T o 19 mpm) .023 ...

  • Miller Electric 22A - page 14

    OM-193 472 Page 10 3-3. Gun Recommendation T able Process Gun GMA W − Hard or Corded Wires M25 Or M40 FCA W − Self-Shielding Wires GA-40GL 1 CV Welding Power Source With 24 V AC Power 2 CV Welding Power Source Without 24 V AC Power 3 1 15 V olts AC /24 V olts AC Power Adapter 4 14-Pin Control Cord 5 Weld Cable (Required) 6 W ork 3-4. Equipment ...

  • Miller Electric 22A - page 15

    OM-193 472 Page 1 1 3-6. 14-Pin Plug Information Pin* Pin Information A 24 volts ac with respect to pin G. A J K B Contact closure to A completes 24 volts ac contactor control circuit. A J B K I G Circuit common for 24 volts AC circuit. B C L N H C +10 volts dc output to remote control with respect to pin D. D M G E F D Remote control circuit commo ...

  • Miller Electric 22A - page 16

    OM-193 472 Page 12 3-8. Optional Meter Circuit Board Settings Ref. 802 357 / Ref. 186 266 T ools Needed: 1/4 in 1 Meter Circuit Board 2 DIP Switch S2 Set DIP switch S2 for type of welding power source, and desired wire feed speed display (see illustration). Reinstall wrapper . 12 3 4 5 12 3 45 12 3 45 123 45 Or Or Meters/Minute Inches/Minute Digita ...

  • Miller Electric 22A - page 17

    OM-193 472 Page 13 3-9. Motor Start/Burnback Control Ref. 802 357 / 192 653 T o change wire feed starting speed proceed as follows: T urn Off unit and welding power source. Remove wrapper . 1 Motor Board PC1 2 Motor Start Control Potentiometer R73 Remove protective white rubber cap before making adjustment. Adjust potentiometer R73 using a small no ...

  • Miller Electric 22A - page 18

    OM-193 472 Page 14 3-10. Installing Wire Guide And Drive Roll 801 923-C Install and secure inlet wire guide on either assembly , and intermediate wire guide on 4 drive roll assembly only . Install drive rolls and turn drive roll nut one click. During maintenance intervals, remove drive rolls, and clean grooves using a wire brush. Check groove of dr ...

  • Miller Electric 22A - page 19

    OM-193 472 Page 15 3-1 1. Installing And Threading W elding Wire T ools Needed: 1 Retaining Ring 2 Hub T ension Adjustment Nut If necessary , move hub on support for use of different size wire spool. Remove retaining ring, and install spool so hub pin fits spool hole. Reinstall retaining ring. Adjust tension nut so wire is taut when wire feed stops ...

  • Miller Electric 22A - page 20

    OM-193 472 Page 16 SECTION 4 − OPERA TION 4-1. Front Panel Controls 1 Optional V oltage/Wire Speed Meter 2 Optional V oltage/Wire Speed Switch Use to choose volts or wire feed speed display . 3 Optional Remote V oltage Control Use to set welding power source voltage at the wire feeder . Numbers are for reference only . 4 Wire Speed Control 5 Jog/ ...

  • Miller Electric 22A - page 21

    OM-193 472 Page 17 4-2. Optional Side Panel Controls Ref. 802 357-A / Ref. 186 589 / 210 436-A 1 Preflow Control Control sets time gas flows before welding wire is energized. T ime range is 0 to 5 seconds. 2 Postflow Control Control sets time gas flows after completion of burnback. Time range is 0 to 5 seconds. 3 Spot Time Control Factory set for 0 ...

  • Miller Electric 22A - page 22

    OM-193 472 Page 18 5-2. Overload Protection Y T urn Off wire feeder and welding power source. Stop engine on welding generator . 1 Circuit Breaker CB1 CB 1 protects wire feeder from over- load. Correct problem and manually reset breaker . 802 349-A 1 5-3. T roubleshooting T rouble Remedy Wire does not feed, unit completely inop- erative. T urn Powe ...

  • Miller Electric 22A - page 23

    OM-193 472 Page 19 SECTION 6 − ELECTRICAL DIAGRAM 210 430-A Figure 6-1. Circuit Diagram For Wire Feeder With Optional Equipment ...

  • Miller Electric 22A - page 24

    OM-193 472 Page 20 SECTION 7 − P ARTS LIST Figure 7.1. Main Assembly 802 358-F . Hardware is common and not available unless listed. 10 Figure 7-2 & Figure 7-3 38 40 39 33 35 36 34 32 31 30 37 45 44 43 16 17 19 15 42 1 41 2 3 5 8 7 9 6 10 11 4 26 28 29 27 21 20 23 24 22 18 25 13 14 12 9 46 ...

  • Miller Electric 22A - page 25

    OM-193 472 Page 21 Figure 7-1. Main Assembly Diagram marking Item No. Part No. Description Quantity 1 089 899 LA TCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 +198 650 WRAPPER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric 22A - page 26

    OM-193 472 Page 22 Diagram marking Item No. Part No. Description Quantity Figure 7-1. Main Assembly (Continued) ♦ 1 15 443 ST AND-OFF , 6-32 x .750 lg 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 197 328 CASE ASSEMBL Y 1 . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric 22A - page 27

    OM-193 472 Page 23 Diagram marking Item No. Part No. Description Quantit y Figure 7-2. Drive Assembly , Wire (2 Drive Roll) (Fig 7-1 Item 40) 1 602 009 SCREW , .250-20 x 1.250 soc hd hex gr 8 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 172 075 CARRIER, drive roll w/component 24 pitch 1 . . . . . . ...

  • Miller Electric 22A - page 28

    OM-193 472 Page 24 Diagram marking Item No. Part No. Description Quantity Figure 7-3. Drive Assembly , Wire (4 Drive Roll) (Fig 7-1 Item 40) 1 602 009 SCREW , .250-20 x 1.250 soc hd hex gr 8 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 172 075 CARRIER, drive roll w/component 24 pitch 4 . . . . . . ...

  • Miller Electric 22A - page 29

    OM-193 472 Page 25 T able 7-1. Drive Roll And Wire Guide Kits (2 Drive Roll) Base selection of drive rolls upon the following recommended usages: 1. V -Grooved rolls for hard wire. 2. U-Grooved rolls for soft and soft shelled cored wires. 3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4. V -Knurled rolls for hard ...

  • Miller Electric 22A - page 30

    OM-193 472 Page 26 T able 7-2. Drive Roll & Wire Guide Kits (4 Drive Roll) Base selection of drive rolls upon the following recommended usages: 1. V -Grooved rolls for hard wire. 2. U-Grooved rolls for soft and soft shelled cored wires. 3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4. V -Knurled rolls for ha ...

  • Miller Electric 22A - page 31

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe ...

  • Miller Electric 22A - page 32

    PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX: 920-735-4134 Int ernati onal F A X: 920-735-4125 European Headqua rters − U ...

Manufacturer Miller Electric Category Welder

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All of them are important, but the most important information from the point of view of use of the device are in the user manual Miller Electric 22A.

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A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Miller Electric 22A by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Miller Electric 22A.

A complete Miller Electric manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Miller Electric 22A - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Miller Electric 22A, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Miller Electric 22A, that we can find in the current document
3. Tips how to use the basic functions of the device Miller Electric 22A - which should help us in our first steps of using Miller Electric 22A
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Miller Electric 22A
5. FAQ - Frequently Asked Questions
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