Miller MigMatic 220, MigMatic 250 Base, MigMatic 220 DX, MigMatic 250 DX, Migmatic 250 Owner's Manual

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Page 1

OM-246 691B 2011−02

Processes

MIG (GMAW) Welding Flux Cored (FCAW) Welding

Description

Arc Welding Power Source Wire Feeder

MigMatic 220/250 Base/DX

Visit our website at

www.MillerWelds.com

OWNER’S MANUAL

File: MIG (GMAW)

Page 2

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 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.

Working as hard as you do

− every power source from Miller is backed by the most hassle-free warranty in the business.

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.

Page 3

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 − DEFINITIONS 5..................................................................

2-1. WEEE Label 7.........................................................................

2-2. Symbols And Definitions 7...............................................................

SECTION 3 − INSTALLATION 8................................................................

3-1. Important Information Regarding CE Products (Sold Within The EU) 8..........................

3-2. Serial Number And Rating Label Location 8................................................

3-3. Specifications 8........................................................................

3-4. Duty Cycle And Overheating 8...........................................................

3-5. Volt-Ampere Curves 9..................................................................

3-6. Installing Gas Supply 9.................................................................

3-7. Installing Wire Spool And Adjusting Hub Tension 10...........................................

3-8. Positioning Jumper Links (230/400V 3-Phase Models) 11......................................

3-9. Electrical Service Guide 12...............................................................

3-10. Selecting a Location and Connecting Input Power (1-Phase and 3-Phase) 13.....................

3-11. Installing Drive Rolls And Wire Guide 15....................................................

3-12. Threading Welding Wire And Adjusting Pressure Roll Tension 16...............................

SECTION 4 − OPERATION 17...................................................................

4-1. Controls For MigMatic 220/250 17.........................................................

4-2. Burnback And Spot Weld Timer Controls 17.................................................

4-3. Controls For MigMatic 220 DX / 250 DX 18..................................................

4-4. Burnback And Spot Weld Timer Controls 18.................................................

4-5. Welding Power Source Input Line Voltage Adjustment (DX Models Only) 19......................

4-6. Welding Power Source Setup Menu (DX Models Only) 20.....................................

4-7. Trigger Mode Selection (DX Models Only) 21................................................

4-8. Spool Gun Mode (DX Models Only) 21.....................................................

4-9. Welding Wire Diameter Selection For Synergic MIG (DX Models Only) 22........................

4-10. Welding Wire Type Selection For Synergic MIG (DX Models Only) 22............................

4-11. Gas Selection For Synergic MIG (DX Models Only) 22........................................

4-12. Selecting Manual MIG Welding (DX Models Only) 23..........................................

4-13. Selecting Synergic MIG Welding (DX Models Only) 24........................................

SECTION 5 − MAINTENANCE &TROUBLESHOOTING 25..........................................

5-1. Routine Maintenance 25.................................................................

5-2. Circuit Breaker CB1 25..................................................................

5-3. Unit Overload 25........................................................................

5-4. Troubleshooting 26......................................................................

SECTION 6 − ELECTRICAL DIAGRAMS 28.......................................................

SECTION 7 − PARTS LIST 32...................................................................

WARRANTY

Page 4

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

ITW Welding Products Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy 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

MIGMATIC 220, 230VAC 029015520

MIGMATIC 220 DX, 230VAC 029015521

MIGMATIC 250 230/400VAC 029015524

MIGMATIC 250 DX, 230/400VAC 029015525

Council Directives:

• 2006/95/EC Low Voltage

• 2004/108/EC Electromagnetic Compatibility

Standards:

• IEC 609741 Arc Welding Equipment  Welding Power Sources: edition 3, 200507.

• IEC 609745 Arc Welding Equipment – Wire Feeders: edition 2, 200711.

• IEC 6097410 Arc Welding Equipment  Electromagnetic Compatibility Requirements: edition 2.0, 200708.

• EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding, arc

welding and allied processes with the basic restrictions related to human exposure to electromagnetic fields (0Hz300Hz)

EU Signatory:

December 13th, 2010

___________________________________________________________________________________

Massimigliano Lavarini Date of Declaration

ELECTRONIC ENGINEER R&D TECH. SUPPORT

956 142 835

Page 5

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

som 2011−01

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 explained in the text.

NOTICE − Indicates statements not related to personal injury.

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.

ELECTRIC SHOCK can kill.

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.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on

unit.

D Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp locations or 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 unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!

D 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).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

D 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.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not drape cables over your body. D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed. D Allow cooling period before working on equip-

ment.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and clothing to prevent burns.

OM-246 691 Page 1

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FUMES AND GASES can be hazardous.

)

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.

D If ventilation is poor, wear an approved air-supplied respirator. D Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

D 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 while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

ARC RAYS can burn eyes and skin.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off compressed gas supply when not in use. D Always ventilate confined spaces or use

approved air-supplied respirator.

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.

D Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant

material (leather, heavy cotton, or wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot

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.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Do not weld where flying sparks can strike flammable material. D Protect yourself and others from flying sparks and hot metal. D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D 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).

D Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

D 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, sparks, and fire hazards.

D Do not use welder to thaw frozen pipes.

OM-246 691 Page 2

workpiece, and hot equipment can cause fires and

ELECTRIC AND MAGNETIC FIELDS (EMF can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

D Wear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

Compressed 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.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder − explosion will result. D Use only correct compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.

Page 7

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.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face. D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.

D Keep away from moving parts. D Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading welding wire.

MOVING PARTS can injure.

D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.

D Use only genuine replacement parts from the manufacturer. D Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local codes.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained. D 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.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as computers and computer-driven equipment such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D 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.

OM-246 691 Page 3

Page 8

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org. OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814 (phone: 301-504-7923, website: www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, access restrictions for passers−by or individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a cable cover.

2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

OM-246 691 Page 4

Page 9

SECTION 2 − DEFINITIONS

Warning! Watch Out! There are possible hazards as shown by the symbols.

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.

1.2 Protect yourself from electric shock by insulating yourself from work and ground.

1.3 Disconnect input plug or power before working on machine.

2 Breathing welding fumes can be

hazardous to your health.

2.1 Keep your head out of the fumes.

2.2 Use forced ventilation or local exhaust to remove the fumes.

2.3 Use ventilating fan to remove fumes.

3 Welding sparks can cause explosion

or fire.

3.1 Keep flammables away from welding. Do not weld near flammables.

3.2 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

3.3 Do not weld on drums or any closed containers.

4 Arc rays can burn eyes and injure

skin.

4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.

5 Become trained and read the

instructions before working on the machine or welding.

6 Do not remove or paint over (cover)

the label.

2 3

1 Warning! Watch Out! There

are possible hazards as

shown by the symbols. 2 Drive rolls can injure fingers 3 Welding wire and drive parts

are at welding voltage during

operation − keep hands and

metal objects away.

OM-246 691 Page 5

Page 10

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 loop of extra length,

connect grounding conductor

first. 5 Connect line input conductors

as shown on inside label −

double-check all connections,

jumper link positions, and

input voltage before applying

power.

1 Warning! Watch Out! There

are possible hazards as

shown by the symbols. 2 Moving parts, such as fans,

can cut fingers and hands and

cause injury. Keep away from

moving parts.

S-176 106

1 Warning! Watch Out! There

are possible hazards as

shown by the symbols.

2 Falling unit can cause injury.

Do not move or operate unit where it could tip.

3 Cylinders can explode if

damaged. Protect compressed gas cylinders from excessive heat, mechanical shock, slag, open flames, sparks, and arcs.

OM-246 691 Page 6

Page 11

2-1. WEEE Label

2-2. Symbols And Definitions

Do not discard this product with general waste.

Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.

Contact your local recycling office or your local distributor for further information.

Amperes

Remote On Off

Line Connection Three Phase Single Phase

Primary Voltage

Rated Welding

Current

Degree Of Protection

Four-Step Trigger

Operation

Voltage Input

I1max

Volts

Rated Maximum

Supply Current I1eff

Duty Cycle Percent

Circuit Breaker

Gas Input Gas Output Gas Type

Wire Feed Spool

Gun

Alternating Current

(AC)

Maximum Effective

Supply Current

Three Phase

Transformer

Rectifier

Wire Feed

Direct Current

Protective Earth

Gas Metal Arc

Welding (GMAW)

Conventional Load

Rated No Load

Voltage (Average)

Two-Step Trigger

Operation

(DC)

(Ground)

Voltage

Hertz

Read Operator’s

Manual

Wire Burnback

Control

Wire Type Diameter

Wire Run-In Speed

Control

Spot Weld Time

OM-246 691 Page 7

Page 12

SECTION 3 − INSTALLATION

3-1. Important Information Regarding CE Products (Sold Within The EU)

! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.

This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure information.

S The EMF assessment on this equipment was conducted at 0.5 meter.

S At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.

3-2. Serial Number And Rating Label Location

The serial number and rating information for this product is located on back panel . Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

3-3. Specifications

Rated Output

Model

220 230 VAC 50/60 Hz

Wire feed speed range 1.3 mpm to 20 mpm.

Model

250

230/400 VAC

50/60 Hz

Wire feed speed range 1.3 mpm to 20 mpm.

100% 60% 20%

90 A

18.5 V

Rated Output

100% 60% 35%

145 A

21.0 V

116 A

19.8 V

190 A

23.0 V

200 A

24.0 V

250 A

26.5 V

Max.

Open

Circuit

Voltage

40.2 30-200 A IP23S 350 x 575 x 920 64 Net

Max. Open

Circuit

Voltage

43.0 V 30-250 A IP23S 350 x 575 x 920 73 Net

Amperage

Range

Amperage

Range

IP Rating

Dimension (mm)

IP Rating

Dimension (mm)

Weight

(kg)

Weight

(kg)

3-4. Duty Cycle And Overheating

35% Duty Cycle At 250 Amperes 100% Duty Cycle At 145 Amperes

3-1/2 Minutes Welding 6-1/2 Minutes Resting

Overheating

% DUTY CYCLE

Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.

If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding.

NOTICE − Exceeding duty cycle can damage unit and void warranty.

Continuous Welding

A or V

OM-246 691 Page 8

Minutes

Reduce Duty Cycle

sduty1 5/95

Page 13

3-5. 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.

3-6. Installing Gas Supply

Model 220

Model 250

MAX

MIN

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 per

Argon Gas

CO2 Gas

minute. Check wire manufacturer’s recommended flow rate. This flow gauge can be adjusted between 2.36 and 11.8 liters per minute.

Ref. ST-148 265-B / Ref. ST-149 827-B / Ref. ST-158 697-A

OM-246 691 Page 9

Page 14

3-7. Installing Wire Spool And Adjusting Hub Tension

Hub Assembly

1 Spacers Use only for 5Kg spool.

15 Kg Wire Spool Assembly

5 Kg Wire Spool Assembly

Tools Needed:

OM-246 691 Page 10

Ref. D2

Page 15

3-8. Positioning Jumper Links (230/400V 3-Phase Models)

! Disconnect and lockout/tag-

out input power before installing or moving jumper links.

Check input voltage available at site. 1 Jumper Link Label Check label − only one is on unit. 2 Jumper Links Move jumper links to match input

voltage. Close and secure access door.

230 Volts

400 Volts

230 Volts

400 Volts

956142718_3-5

OM-246 691 Page 11

Page 16

3-9. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

. Power cord supplied with unit is sized for 230 volt operation. Larger power cord may be required for cable length greater than 3 meters. Consult

national or local regulations.

MigMatic Model

Input Voltage (V) 230 230 400 Input Amperes (A) At Rated Output 34 28 16 Max Recommended Standard Fuse Rating In Amperes

Time-Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In mm2 (AWG)

Max Recommended Input Conductor Length In Meters (Feet)

Min Grounding Conductor Size In mm2 (AWG)

Reference: 2008 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248.

3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and

above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

50/60 Hz Single Phase

220

50/60 Hz Three Phase

40 30 15 50 40 25

10 (8) 6 (10) 4 (12)

(134)

6 (10) 6 (10) 4 (12)

(124)

250

(226)

Notes

OM-246 691 Page 12

Page 17

3-10. Selecting a Location and Connecting Input Power (1-Phase and 3-Phase)

A. 1-Phase

! Installation must meet all National

and Local Codes − have only qualified persons make this installation.

! Disconnect and lockout/tagout in-

put power before connecting input conductors from unit.

! Always connect green or green/

yellow conductor to supply grounding terminal first, and never to a line terminal.

1 Black And White Input Conductor

(L1 And L2)

2 Green Or Green/Yellow Grounding

Conductor 3 Input Power Cord. 4 Disconnect Device (switch shown in

the OFF position) 5 Disconnect Device Grounding

Terminal 6 Disconnect Device Line Terminals Connect green or green/yellow grounding

conductor to disconnect device grounding terminal first.

Connect input conductors L1 and L2 to disconnect device line terminals.

7 Over-Current Protection Select type and size of over-current

protection using Section 3-9 (fused disconnect switch shown).

Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.

18 in (457 mm)

for airflow

Earth Ground

=GND/PE

Tools Needed:

Ref. D4

OM-246 691 Page 13

Page 18

B. 3-Phase

! Installation must meet all National

and Local Codes − have only quali-

= GND/PE Earth Ground

fied persons make this installation.

! Disconnect and lockout/tagout in-

put power before connecting input

conductors from unit.

! Always connect green or green/

yellow conductor to supply

grounding terminal first, and never

to a line terminal. For Three-Phase Operation

1 Input Power Cord. 2 Disconnect Device (switch shown in

the OFF position) 3 Green Or Green/Yellow Grounding

Conductor 4 Disconnect Device Grounding

Terminal 5 Input Conductors (L1, L2 And L3) 6 Disconnect Device Line Terminals Connect green or green/yellow grounding

conductor to disconnect device grounding terminal first.

Connect input conductors L1, L2, and L3 to disconnect device line terminals.

7 Over-Current Protection Select type and size of over-current

protection using Section 3-9 (fused disconnect switch shown).

Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.

Tools Needed:

OM-246 691 Page 14

Ref. D5

Page 19

3-11. Installing Drive Rolls And Wire Guide

Tools Needed:

1 Inlet Wire Guide Securing

Screw 2 Inlet Wire Guide Loosen screw. Slide tip as close to

drive rolls as possible without touching. Tighten screw.

3 Drive Roll The drive roll consists of two differ-

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.

4 Drive Roll Securing Screw Tighten screw to secure drive roll.

Notes

2.5 mm

956142721_2-2

OM-246 691 Page 15

Page 20

3-12. 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 Lay gun cable out straight.

Tools Needed:

. 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;

Tighten

. Use pressure indicator

scale to set a desired drive roll pressure.

1 2 3 4

Pressure

Indicator

Scale

continue to hold wire.

Close and tighten pressure

assembly, and let go of wire.

Press gun trigger until wire comes out of gun. Reinstall

contact tip and nozzle

OM-246 691 Page 16

Remove gun nozzle and contact tip. Turn On.

Tighten

1 2 3

WOOD

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close

and latch door.

956142715_3-5/956142715_4-5

Page 21

SECTION 4 − OPERATION

4-1. Controls For MigMatic 220/250

1 Power Switch S1 Use switch to turn power on and off. 2 Voltage Control S2 Turn control clockwise to increase

voltage. 3 High Temperature Shutdown

Light PL2 (Orange LED)

4 Power Indicator Light PL1

(White LED) 5 Wire Feed Speed Control R1 Turn control clockwise to increase

wire feed speed. 6 MIG Torch Connection Connection for Euro style MIG gun. 7 Work Lead Connection

4-2. Burnback And Spot Weld Timer Controls

956142715_5-5

1 Burnback Control R3 Time that welding wire stays ener-

gized after trigger is released.

2 Spot Weld Timer R2 Time that welding arc is active be-

fore shutting off automatically. Spot Timer resets after releasing

gun trigger.

956142715_3-5

OM-246 691 Page 17

Page 22

4-3. Controls For MigMatic 220 DX / 250 DX

14 13

1 Power Switch S1 Use switch to turn power on and off. 2 Voltage Control S2 Turn control clockwise to increase voltage. 3 High Temperature Shutdown Light

PL2-(Orange LED)

4 Power Indicator Light PL1 (White

LED)

5 Wire Feed Speed (WFS)/Trim (Arc

Length) And Line Input Adjustment

Control R1 (See Section 4-5) 6 MIG Torch Connection Connection for Euro style MIG gun. 7 Work Lead Connection 8 Spool Gun Connection 7-pin Plug

Receptacle 9 Digital Display Meter Displays values and parameters for selec-

ted welding process 10 Setup Button Use button to select parameters (V, A, %),

and to change from manual to synergic MIG modes.

11 Trigger Mode Button Use control to select desired trigger mode

(see Section 4-7). 12 Wire Diameter Push Button Use control to Select desired welding wire

diameter for synergic MIG process (see Section 4-9).

13 Material Button Use control to select material type for syn-

ergic MIG process (see Section 4-10). 14 Gas Selection Button Use control to select desired welding gas

type for synergic MIG process (see Section 4-11).

956142718_5-5

4-4. Burnback And Spot Weld Timer Controls

OM-246 691 Page 18

1 Burnback Control R3 Use control to set time welding wire

stays energized after trigger is released.

2 Wire Run-In Speed Control

Use control to determine rate at which welding wire feeds before an arc is initiated.

956142718_4-5

Page 23

4-5. Welding Power Source Input Line Voltage Adjustment (DX Models Only)

1 Wire Feed Speed (WFS)/Trim

(Arc Length) And Line Input Adjustment Control R1

2 Wire Feed Speed Indicator

Scale (Manual Mode)

3 Input Line Voltage Adjustment

Center Indicator (Synergic

958

Mode)

4 Input Line Voltage/Wire Speed

Adjustment Indicator Scale (Synergic Mode)

Before power up, turn control R1 to the center position.

Within 5 seconds of power up, unit verifies value of input line voltage, and if necessary, makes correction based on a percentage of preset (synergic) parameters.

5 Power Indicator Light PL1 6 Digital Meter Display The required type of input voltage

correction (plus or minus) is displayed on digital meter as follows:

7 Negative Percentage Input Line

Voltage Adjustment Display Indicator

• A dash in the left segment of the

meter and a flashing PL1 indicates the need for a negative correction. Turn R1 counterclockwise to decrease value.

8 Positive Percentage Input Line

Voltage Adjustment Display Indicator

• A dash in the right segment of the

meter and a flashing PL1 indicates the need for a positive correction. Turn R1 clockwise to increase value.

9 Correct Input Line Voltage

Display Indicator

• A dash in the center segment of the

meter indicates the input voltage is correct.

Input line voltage compensations are made each time the unit is turned on.

. Fluctuations in input line voltage

that occur more than five seconds after power up are not automatically compensated for. The operator must manually adjust for incorrect input line voltage by rotating control R1.

Correct adjustment is confirmed by a beeping or buzzer signal, while a flashing power indicator light PL1 indicates an incorrect input line voltage.

. While PL1 is flashing, the ma-

chine will continue to operate, but weld output characteristics may be affected.

After correct input line voltage has been established, 220 or 250 (depending on model) is displayed on the meter.

. Each time the machine is turned

on, the last setting is displayed

OM-246 691 Page 19

Page 24

4-6. Welding Power Source Setup Menu (DX Models Only)

1 Wire Feed Speed (WFS)/Trim

(Arc Length) And Line Input

Adjustment Control R1 2 Synergic Mode Indicator 3 Voltage LED 4 Digital Display Meter 5 Amperage LED 6 Wire Feed Speed LED 7 Setup Button 8 Manual Mode Indicator 9 Voltage Control 10 Trigger Mode Button Use setup button to select desired

parameter: voltage, amperage, or preset wire feed speed and lite corresponding LED (V, A, or %).

Rotate Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control to change wire feed speed or amperage, depending upon which parameter is active.

Rotate voltage control to change voltage when voltage LED is lit.

The value of the selected parameter is displayed on display meter.

. The default for preset wire feed

speed is meters per minute. To

change to inches per minute,

press and hold setup and trig-

ger function buttons for approx-

imately 5 seconds.

Selecting Manual Or Synergic Mode

Press and hold setup button for approximately 3 seconds to switch between manual mode (see Section 4-12) and synergic mode (see Section 4-13), and lite corresponding mode indicator LED .

OM-246 691 Page 20

Page 25

4-7. Trigger Mode Selection (DX Models Only)

. Always select a trigger mode.

1 2T Trigger Mode When trigger is pressed welding starts.

When trigger is released, welding stops. 2 4T Trigger Mode When trigger is pressed, welding starts.

When trigger is released, welding continues. When trigger is pressed and released a second time, welding stops.

3 Trigger Mode Selection Button Press button to select desired trigger mode

and lite corresponding LED.

. 2T and 4T trigger methods work in both

manual and synergic modes.

4 Spool Gun Mode (See Section 4-8)

4-8. Spool Gun Mode (DX Models Only)

1 Spool Gun Mode Indicator LED Connect spool gun to 7-pin spool gun re-

ceptacle (see Section 4-3). With spool gun connected and power

source in the manual mode, the manual mode indicator LED is lit (see Section 4-6), and wire feed speed is controlled with the potentiometer on the spool gun.

While in the synergic mode, the synergic mode indicator LED is lit. Use only aluminum welding wire in the synergic mode.

. When spool gun is connected, 2T and

4T trigger modes are disabled.

. For 2T and 4T trigger operation, see

Section 4-7.

OM-246 691 Page 21

Page 26

4-9. Welding Wire Diameter Selection For Synergic MIG (DX Models Only)

1 Welding Wire Diameters 2 Welding Wire Diameter

Button Press button to select desired wire

diameter: 0.6 mm, 0.8 mm, 1.0 mm, or 1.2 mm, and lite corresponding LED.

4-10. Welding Wire Type Selection For Synergic MIG (DX Models Only)

1 Welding Wire Types 2 Welding Wire Type Button Press button to select desired wire

type: Fe (ferris), CrNi (stainless steel), Al (aluminum), or CuSi (Copper Silicon), and lite corresponding LED.

4-11. Gas Selection For Synergic MIG (DX Models Only)

1 Shielding Gas Types 2 Gas Selection Button Press button to select desired

shielding gas type: CO Dioxide), Mix (ArCO2), Arg (Argon), and lite corresponding LED.

(Carbon

OM-246 691 Page 22

Page 27

4-12. Selecting Manual MIG Welding (DX Models Only)

1 2

1 Setup Button 2 Manual MIG Mode Indicator Press and hold setup button for ap-

proximately 3 seconds to select

manual MIG mode and lite indicator. 3 Voltage Control S2 4 Wire Feed Speed (WFS)/Trim

(Arc Length) And Line Input Adjustment Control R1

5 Digital Display Meter

. In Manual MIG mode, the operat-

or may need to adjust main welding parameters for specific arc characteristics

Use setup button to select desired parameter: voltage, amperage, or preset wire feed speed and lite corresponding LED (V, A, or %).

The value of the selected parameter is displayed on meter.

Turn voltage control clockwise to increase voltage.

Turn wire feed speed control clockwise to increase wire feed speed.

Select trigger mode 2T or 4T according to Section 4-7.

Spool Gun Operation:

6 Spool Gun Receptacle For spool gun connection and opera-

tion, see section 4-8.

OM-246 691 Page 23

Page 28

4-13. Selecting Synergic MIG Welding (DX Models Only)

1 Setup Button 2 Synergic MIG Mode Indicator Press and hold Setup button for ap-

proximately 3 seconds to select syn-

ergic MIG mode and lite indicator. 3 Voltage Control S2 4 Wire Feed Speed (WFS)/Trim

(Arc Length) And Line Input Adjustment Control R1

5 Digital Display Meter

. In synergic MIG mode, the oper-

ator may have to adjust welding data for specific arc characteristics. Generally voltage is adjusted and the synergic process automatically sets appropriate wire feed speed.

Use setup button to select desired parameter: voltage, amperage, or preset wire feed speed and lite corresponding LED (V, A, or %).

The value of the selected parameter is displayed on meter.

Turn voltage control S2 clockwise to increase voltage.

Turn wire feed speed control R1 clockwise to increase wire feed speed.

6 Trigger Mode Button Use button to select 2T or 4T (see

Section 4-7). 7 Wire Diameter Button Use button to select desired wire

diameter. 8 Welding Wire Type Button Use button to select appropriate

welding wire type. 9 Gas Selection Button Use button to select desired shield-

ing gas.

Spool Gun Operation:

10 Spool Gun Receptacle For spool gun connection and oper-

ation, see section 4-8.

OM-246 691 Page 24

Page 29

SECTION 5 − MAINTENANCE &TROUBLESHOOTING

5-1. Routine Maintenance

3 Months

Replace unreadable labels

Clean and tighten weld terminals

6 Months

Blow out or vacuum inside.

! Disconnect power

before maintaining.

Repair or replace cracked weld cable

Remove drive roll and carrier. Apply light coat of oil or grease to drive motor shaft.

. Maintain more often

during severe conditions.

5-2. Circuit Breaker CB1

5-3. Unit Overload

1 Circuit Breaker CB1 CB1 protects the unit from over-

loading of drive motor M1. If CB1 opens, wire feeding stops.

2 Welding Gun Check gun liner for blockage or

kinks. 3 Wire Drive Assembly Check for jammed wire, binding

drive gear or misaligned drive rolls. Allow cooling period and reset

breaker. Close door.

Thermal switches TP1 in SR1 and TP2 in XFMR protect the unit from damage due to overheating. If the thermal indicator illuminates, wait for unit to cool allowing fan motor to run before trying to weld. If unit is cool and no weld output continues, contact Factory Authorized Service Agent.

OM-246 691 Page 25

Page 30

5-4. Troubleshooting

Trouble Remedy

No weld output; wire does not feed.

Be sure line disconnect switch is On (see Section 3-10).

Replace building line fuse or reset circuit breaker if open (see Section 3-10).

Reset circuit breaker CB1 (see Section 5-2).

Secure gun trigger connections.

Check continuity of power switch S1 and replace if necessary.

Have Factory Authorized Service Agent check main transformer T1 for signs of winding failure. Check continuity across windings and check for proper connections. Check secondary voltages. Replace T1 if necessary.

Have Factory Authorized Service Agent check continuity of thermostats TP1 and TP2. Replace TP1 and TP2 if necessary.

Have Factory Authorized Service Agent check main control board PC1 and connections, and replace if necessary.

No weld output; wire feeds.

Low weld output.

Low, high, or erratic wire speed. Readjust front panel settings (see Section 4-1).

Connect work clamp to get good metal to metal contact.

Replace contact tip (see gun Owner’s Manual).

An overload condition occurred (see Section 5-3)

Have Factory Authorized Service Agent check diodes in main rectifier SR1, and replace if necessary.

Have Factory Authorized Service Agent check stabilizer Z1 for signs of winding failure. Check continuity across windings and check connections. Replace Z1 if necessary.

Have Factory Authorized Service Agent check main transformer T1 for signs of winding failure. Check continuity across windings and check connections. Check secondary voltages. Replace T1 if necessary.

Have Factory Authorized Service Agent check voltage switch(s). Replace if necessary.

Connect unit to proper input voltage or check for low line voltage (see Section 3-8).

Check input voltage jumper links and correct position if necessary (see Section 3-8).

Have Factory Authorized Service Agent check main rectifier SR1, and replace if necessary.

Have Factory Authorized Service Agent check voltage switch(s). Replace if necessary.

Adjust input line voltage (see Section 4-5).

Change to correct size drive rolls.

Readjust drive roll pressure (see Section 3-12).

Replace inlet guide, contact tip, and/or liner if necessary.

Check position of input jumper links (see Section 3-8).

Have Factory Authorized Service Agent check Wire Speed control R1, and replace if necessary.

Have Factory Authorized Service Agent check diodes in main rectifier SR1, and replace if necessary.

Have Factory Authorized Service Agent check main control board PC1 and connections and replace if necessary.

No wire feed.

OM-246 691 Page 26

Reset circuit breaker CB1 (see Section 5-2).

Rotate Wire Speed control R1 to higher setting (see Sections 4-1 and 4-3).

Clear obstruction in gun contact tip or liner (see gun Owner’s Manual).

Page 31

Notes

OM-246 691 Page 27

Page 32

SECTION 6 − ELECTRICAL DIAGRAMS

Figure 6-1. Circuit Diagram for Migmatic 220 (230 VAC)

OM-246 691 Page 28

956142709-C

Page 33

Figure 6-2. Circuit Diagram for Migmatic 250 (230/400 VAC)

956142710-B

OM-246 691 Page 29

Page 34

Figure 6-3. Circuit Diagram for Migmatic 220 DX (230 VAC)

OM-246 691 Page 30

956142711-F

Page 35

Figure 6-4. Circuit Diagram for Migmatic 250 DX (230/400 VAC)

956142712-E

OM-246 691 Page 31

Page 36

SECTION 7 − PARTS LIST

Figure 7-1. Wrapper Assembly, All Models

956142718_2-5-A

OM-246 691 Page 32

Page 37

Item

No.

Part

No.

Description

Quantity

Figure 7-1. Wrapper Assembly, All Models

Base

1 156034005 Catch, side panel 1 1... ....... .. ............................................ .......

2 156007042 Side Panel, hinged 1 1... ....... .. ........................................... .......

3 156034006 Hinge 2 2... ....... .. ...................................................... .......

4 156005145 Cylinder Rack, upper support 1 1... ....... .. .................................. .......

5 000207235 Label, warning, tilt 1 1... ....... .. ............................................ .......

6 956142682 Rating Plate, MigMatic 220 1... ....... .. .................................... .........

6 956142684 Rating Plate, MigMatic 220 DX 1 1... ....... .. ................................ .......

6 956142683 Rating Plate, MigMatic 250 1... ....... .. .................................... .........

6 956142685 Rating Plate, MigMatic 250 DX 1 1... ....... .. ................................ .......

7 000207291 Label, primary power connections 1 1... ....... .. .............................. .......

8 156023157 Wheel, retaining clip 2 2... ....... .. .......................................... .......

9 056 054082 Wheel, rear, 200 O.D 2 2... ....... .. ......................................... .......

10 156009132 Washer 4 4... ....... .. ..................................................... .......

11 156012137 Axle, rear wheel 1 1... ....... .. ............................................. .......

12 +156122080 Cover, right side 1 1... ...... .. ............................................. .......

13 056054083 Wheel/Caster, front 80 O.D 2 2... ....... .. .................................... .......

14 356029212 Nameplate, lower, front, MigMatic 220/250 1 1... ....... .. ...................... .......

15 156118060 Plastic, lower, front, MigMatic 220/250 1 1... ....... .. .......................... .......

16 656002019 Handle 1 1... ....... .. ..................................................... .......

17 156118061 Plastic, upper, front, MigMatic 220/250 1 1... ....... .. .......................... .......

18 356029210 Nameplate, upper, front, MigMatic 220/250 1... ....... .. ...................... .........

18 356029209 Nameplate, upper, front, MigMatic 220 DX/250 DX 1 1... ....... .. ............... .......

19 000207233 Label, general precautionary 2 2... ....... .. .................................. .......

20 +156122081 Side Panel, left side, lower 1 1... ...... .. .................................... .......

21 156009137 Washer, D. 12 x 36 2 2... ....... .. ........................................... .......

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-246 691 Page 33

Page 38

Figure 7-2. Main Assembly for MigMatic 220

956142716

OM-246 691 Page 34

Page 39

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 7-2. Main Assembly for MigMatic 220

1 156 012 138 Spool Holder, shaft 1... ........... .. .............................................

2 656 009 004 Washer, 17x70, plastic 1... ........... .. ..........................................

3 656 102 007 Hub 1... ........... .. ..........................................................

4 156 009 134 Washer , flat 1... ........... .. ..................................................

5 156 032 136 Spring, 17x3x6 L.40 1... ........... .. ............................................

6 056 020 072 Handwheel Reel, W/Ring 1... ........... .. .......................................

7 156 015 027 Spool Nut, plastic 1... ........... .. ..............................................

8 F1 *056 092 097 Fuse, 2A 5 0 0 V 1... ...... . .. ..............................................

9 000 207 076 Knob, pointer, d.22 2... ........... .. .............................................

10 356 029 214 Nameplate, inner, MigMatic 220/250 1... ........... .. ..............................

11 156 008 040 Spacer, wire feeder, plastic 1... ........... .. ......................................

12 057 021 023 Wire Drive System, 2 roll, d.48 1... ........... .. ...................................

13 556 090 042 Wire Guide, outlet 1... ........... .. ..............................................

14 057 052 047 Connector, minieuro, quick female 1... ........... .. ................................

15 956 142 714 Label, box consumable 1... ........... .. .........................................

16 116 039 030 Box Protection, pcb 1... ........... .. ............................................

17 S2 056 067 266 Switch, 25A 10 pos 1... ...... . .. .............................................

18 R1 056 059 284 Potentiometer, 1Kohms, linear, straight pins 1... ..... . .. .......................

19 PL1 056 072 079 Pilot, 24V lamp, white 1... ..... . .. ..........................................

20 PL2 056 072 080 Pilot, 24V lamp, orange 1... ..... . .. .........................................

21 000 207 075 Knob, pointer, d.6 1... ........... .. ..............................................

22 056 020 069 Knob, pointer, d.7 1... ........... .. ..............................................

23 156 118 062 Panel, front 1... ........... .. ...................................................

24 S1 056 067 267 Switch, primary power on/off 1... ...... . .. ....................................

25 056 076 260 Dinse Socket, female, 50 mmq. 1... ........... .. ..................................

26 T1 058 021 146 Transformer, 230V, 60x80 Al. 1... ...... .. .. ....................................

27 Z 057 098 018 Choke, 230V, D.7, 340x60 Al. 1... ...... .. .. ....................................

28 R4 056 059 285 Resistance, 3ohms, D.16 L90. 1... ..... . .. ..................................

29 000 178 937 Label, warning electric shock 1... ........... .. ....................................

30 +156 122 082 Plate, baffle 1... .......... .. ...................................................

31 SR1 056 050 156 Rectifier, PMS 20/4/2F 1... ..... . .. ..........................................

32 TP1 056 159 028 Thermostat, 100 ° 10A 1... ..... . .. .........................................

33 656 026 123 Hose, gas, braided, black, D. 5x8, 10 bar 1... ........... .. .........................

34 156 005 146 Corner Seal, plastic, r. 15 2... ........... .. .......................................

35 R2 056 059 286 Potentiometer, 100 Kohms, W/Switch straight pins 1... ..... . .. .................

36 R3 056 059 287 Potentiometer, 10 Kohms, linear, straight pins 1... ..... . .. .....................

37 056 092 098 Fuse Holder, 6.3A 2 5 0 V 1... ........... .. .......................................

38 CB1 056 067 268 Circuit Breaker, 4A 1... ..... . .. .............................................

39 PC1 057 084 142 Circuit Board, control 1... ..... . .. ...........................................

40 T2 058 021 147 Transformer, auxiliary 1... ...... .. .. ...........................................

41 C1 056 082 100 Capacitor, 22000MF 63V 3... ..... . .. ........................................

42 056 070 041 Auxiliary Contacts, BL/X2 N C 1... ........... .. ...................................

43 W 057 079 036 Contactor, 24V 16A 4NA CN−1 6 1... ...... .. .. .................................

44 156 005 147 Plate, support, black 1... ........... .. ............................................

45 000 155 436 Label, ground 2... ........... .. .................................................

46 156 118 063 Base 1... ........... .. .........................................................

47 FM 057 035 019 Motor, fan 2... ..... . .. .....................................................

48 156 118 065 Panel, rear 1... ........... .. ....................................................

49 000 176 106 Label, fan 1... ........... .. .....................................................

50 GSV 056 061 068 Solenoid, gas valve, 24VAC 1... ..... . .. .....................................

51 356 029 215 Nameplate, rear, input gas, MigMatic 220/250 1... ........... .. .....................

52 220 805 Nut, plastic 1... ............... .. ....................................................

53 656 089 041 Clamp 1... ........... .. ........................................................

54 256 071 010 Line Cable, neoprene, mt 3x4. 1... ........... .. ...................................

+When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts.

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Figure 7-3. Main Assembly for MigMatic 220 DX

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956142719-A

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