Miller Electric INTEGRA 201-241 User Manual

OM-188 414C January 2000

Effective with serial number : 165 748

Processes

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Description

Arc Welding Power Source and
Wire Feeder

INTEGRA 201/241

Visit our website at

www.MillerWelds.com

S

0

I

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.

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.

Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . .

1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Duty Cycle and Overheating 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Volt-Ampere Curves 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Installing Gas Supply 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Installing Drive Roll and Wire Inlet Guide 7. . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Installing Wire Spool and Adjusting Hub Tension 7. . . . . . . . . . . . . . . . . . .

2-7. Electrical Service Guide 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Selecting a Location and Connecting Input Power 8. . . . . . . . . . . . . . . . . .

2-9. Installing Work Clamp 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Controls 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 10. . . . . . . . . . . . . . .

4-1. Routine Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Circuit Breaker CB1 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Unit Overload 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Troubleshooting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – ELECTRICAL DIAGRAM 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – PARTS LIST 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

Declaration of Conformity

Manufactruer’s Name:

Manufacturer’s Address:

MILLER Europe S.P.A.

Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy

Declares that this product:

INTEGRA 201/241

Conforms to the following Directives and Standards:

Directives

Electromagnetic Compatibility Directives: 89/336/EEC

Low Voltage: 73/23/EEC

Machinery Directives: 89/392/EEC

And their amendments 91/368/EEC, 93/31/EEC, 93/44/EEC, 93/68/EEC

Standards

Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995

Safety Requirements for Arc Welding Equipment Part 1: EN 60974-1: 1989

European Contact: Mr. Luigi Vacchini, Managing Director

MILLER Europe S.P.A.
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy

Telephone: [phone]

Fax: [phone]

dec_con 5/97

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

som _nd_4/98

Y Marks a special safety message.

. Means “Note”; not safety related.

1-2. Arc Welding Hazards

Y 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 1-4. Read and follow all
Safety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y 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

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 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.

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 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.

power circuit and machine internal circuits are also

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

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 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 after removal of
input power on inverters.

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

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

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 exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.
D Read 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 th e 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 if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.

OM-188 414 Page 1

ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

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 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 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 and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and 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 Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
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 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 Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes.
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.

workpiece, and hot equipment can cause fires and

FLYING METAL 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.

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

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.
D Wearers should consult their doctor before

going near arc welding, gouging, or spot
welding 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.

Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, 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 shielding gas cylinders, regulators, hoses, and fit-

tings 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 Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety
Standards.

OM-188 414 Page 2

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 UNIT can cause injury.

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.

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.

STATIC (ESD) can damage PC boards.

MOVING PARTS can cause injury.

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

closed and securely in place.

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.

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 cause injury.

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

rolls.

WELDING WIRE can cause injury.

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.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten­dent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society ,
550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Batterymarch Park, Quincy, MA 02269.

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 t o 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.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-188 414 Page 3

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Ma g netic Fields

Welding current, as it flows through welding cables, will cause electro­magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

To reduce magnetic fields in the workplace, use the following
procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

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

4. Keep welding power source and cables as far away from opera­tor as practical.

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

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.

OM-188 414 Page 4

SECTION 2 – INSTALLATION

2-1. Specifications

Rated Output

Model

201

241

Wire feed speed range 1.8 mpm to 18 mpm.
* While idling

2-2. Duty Cycle and Overheating

100% 60% 20%

90 A

18.5 V
115 A

20 V

116 A

20 V

150 A

21 V

300

250

200

150

200 A

24 V

240 A

26 V

Max. Open

Circuit Voltage

38

41

Rated Input

Amperage at Rated

Output

230 V

26A

2A*

35A

2.5A*

Dimension (mm) Weight (kg)

310 x 540 x 957 70

310 x 540 x 957 80

Duty Cycle is percentage of 10 mi n ­utes 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.

Y Exceeding duty cycle can

damage unit and void
warranty.

WELDING AMPERES

100

90
80

20 30 40 50 60 70 80 90 100

% DUTY CYCLE

60% Duty Cycle at 200 Amperes

6 Minutes Welding 4 Minutes Resting

Overheating

0

Minutes

15

241

201

40% Duty Cycle at 250 Amperes

4 Minutes Welding 6 Minutes Resting

A or V

OR

Reduce Duty Cycle

duty1 4/95 – SB-150 215

OM-188 414 Page 5

2-3. Volt-Ampere Curves

Model 201

Model 241

1 Normal 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.

dwg. 802004, 802003

2-4. Installing Gas Supply

1

2

3

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 20 cfh (cubic

feet per hour). Check wire man­ufacturer’s recommended flow
rate. This flow gauge can be
adjusted between 5 and 25 cfh.

Argon Gas

OR

OM-188 414 Page 6

CO2 Gas

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

2-5. Installing Drive Roll and Wire Inlet Guide

3

5

2

4

1

2-6. Installing Wire Spool and Adjusting Hub Tension

When a slight force is needed to turn spool, tension is set.

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

drive rolls as possible without touch­ing. Tighten screw.

3 Wire T ension Wheel
4 Drive Roll
Install correct drive roll for wire size

and type.
5 Drive Roll Tension Assembly
Turn nut one click to secure drive

roll.

ST-150 227-C

Tools Needed:

15/16 in

ST-072573-B

2-7. Electrical Service Guide

201 241

Input Voltage
Input Amperes at Rated Output
Max Recommended Standard Fuse or Circuit Breaker Rating in Amperes
** Input Conductor Size in mm
** Grounding Conductor Size in mm

** Power cord supplied with the unit is sized for 230V operation. Larger power cord may be required for cable lengths greater than 3 meters. C
onsult national and local regulations.

2

2

230 230

26 35
26 35

4 4
4 4

OM-188 414 Page 7

2-8. Selecting a Location and Connecting Input Power

18 in (457 mm)

for airflow

Have only qualified persons make
this installation.

1 Rating Label
Supply correct input power.

GND/PE

S

0
I

2-9. Installing Work Clamp

2

1

GND/PE

Connect First

1

L1

3

4

L2

ST-801 721

1 Wire Feeder Connection
2 Work Connect
3 Negative Power Source

Terminal

4 Positive Power Source

Terminal

OM-188 414 Page 8

3-1. Controls

9

SECTION 3 – OPERATION

1

2

3
4

5

6

1 Handle
2 Wire Speed Control
3 Pilot Light
4 Spot Timer
5 Optional Amperage and Volt-

meter
6 Power Switch
7 Thermal Overload Pilot Light
8 10 Position Voltage Control
9 Torch Connector

7

8

OM-188 414 Page 9

SECTION 4 – MAINTENANCE AND TROUBLESHOOTING

4-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replace un readable labels.

Clean and tighten weld terminals.

6 Months

Blow out or vacuum inside. during
heavy service clean monthly.

4-2. Circuit Breaker CB1

Repair or replace
cracked weld cable.

OR

1 Circuit Breaker CB1
If CB1 opens, wire feeding stops.
2 Drive Roll Assembly

1

2

4-3. Unit Overload

If unit is used beyond capacity (excessive wire feed, shorted output, etc.), wire feeds but is not energized. Release gun
trigger to reset this condition.

OM-188 414 Page 10

4-4. Troubleshooting

Trouble Remedy

No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-8).

Replace building line fuse or reset circuit breaker if open (see Section 2-8).
Reset circuit breaker CB1 (see Section 4-2).
Secure gun trigger connections.
Check and replace Power switch if necessary.

No weld output; overload light on Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled

Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 2-8).
No wire feed. Reset circuit breaker CB1 (see Section 4-2).

Poor weld bead, or welding
wire is noodle welding.

(see Section 2-2).
An overload condition occurred. Release gun trigger (see Section 4-3).

Turn Wire Speed control to higher setting (see Section 3-1).
Clear obstruction in gun contact tip or liner.
Readjust drive roll pressure.
Change to correct size drive rolls (see Section 2-5).
Check gun trigger and leads. Repair or replace gun if necessary.
Have Factory Authorized Service Agent check main control board.
Check polarity setting for type of welding wire being used.

OM-188 414 Page 11

SECTION 5 – ELECTRICAL DIAGRAM

5.1 INTEGRA 201

L

N

cod.956.142.275

BLACK
NERO

10 0

5.2 INTEGRA 241

L

N

JACK FEM.

ROSSO
RED

cod.956.142.211

cod.956.142.211

OM-188 414 Page 12

10 0

SECTION 6 – PARTS LIST

6.1 Common Parts Assembly

1

17

13

18

8

2

4

7

6

11

9

10

3

16

15

Item

10 116005316 UV.0.0.17 1

Dia

Ref. Code Qty.Dwg

1 000151187 PV.0.0.18 1
2 116122284 UV.0.0.14 1
3 156087017 2
4 156009067 2
6 056054064 VS.0.0.13 2
7 116005165 DZ.0.0.25 1
8 150005001 1
9 156011002 2

14

6

12

Item

11 156012109 UV.0.0.21 1
12 116121100 UV.0.0.15 1
13 156034001 BP.2.0.19 2
14 057014063 UV.0.7 1
15 056054055 QF.5.0.2 2
16 156002018 QF.0.0.13 1
17 116122285 UV.0.0.16 1
18 116123001 DU.0.0.6 1

Dia

Ref. Code Qty.Dwg

4

OM-188 414 Page 13

6.2 Main Assembly

12

11

10

9

8

7

6

14

13

15

18

16

19

17

20

21

22

23

26

24

25

27

23

22

28

29

30

31

32

5
4

2

3

48

1

46

43

Item

10 156032112 MD.4.2.3 1 1
11 056018001 MD.4.2.2 1 1
12 156019671 MD.4.2.1 1 1
13 156017053 MD.4.3.1 1 1
14 156017054 MD.4.3.2 1 1
15 M 057010048 QF.0.23 1 1
16 F1 056092039 FZ.4.0.5 1 1
17 000046432 OL.0.0.14 1 1
18 156018033 1 1
19 156009079 1 1
20 156022064 GF.1.0.4 1 1
21 156009075 GF.1.0.2 1 1
22 000010191 FU.1.0.6 4 4
23 000058628 FU.1.0.7 2 2
24 656102001 BH.0.0.3 1 1

Dia

Ref. Code

1 056052033 MD.4.0.1 1 1
2 156019694 FZ.0.9.1 3 3
3 156019672 MD.4.0.6 1 1
4 OPTIONAL 156053040 DIA 0.6 V 1 1
4 OPTIONAL 156053036 DIA 0.8 V 1 1
4 OPTIONAL 156053037 DIA 1.0 V 1 1
4 OPTIONAL 156053038 DIA 1.2 V 1 1
4 OPTIONAL 156053041 DIA 1.2 K 1 1
4 OPTIONAL 156053042 DIA 1.0 U 1 1
4 OPTIONAL 156053043 DIA 1.2 U 1 1
5 156076072 MD.4.0.5 1 1
6 556090033 MD.5.0.1 1 1
7 156076073 MD.4.2.7 1 1
8 656064001 MD.4.2.5 1 1
9 156009112 MD.4.2.4 1 1

Dwg 201 241 Item

Qty.

47

44

45

42

33

49

37

38

36

41

Dia

Ref. Code

25 116009041 CV.0.0.2 1 1
26 CB 056067188 UV.0.0.9 1 1
27 PC 028061049 QF.6 1 1
28 056076152 DD.0.0.7 2 2
29 057014065 UT.0.21 1 1
30 027061016 QF.0.21 1 1
31 057014063 UV.0.7 1 1
32 W 057079026 QF.0.20 1
32 W 057079027 UV.0.12 1
33 056091041 QF.0.0.12 1 1
34 T2 058021081 QF.7 1 1
35 FM 056126062 UR.0.0.7 2 2
36 056082091 VU.0.0.4 4 4
37 GS 056061042 UV.0.0.7 1 1
38 S2 056067189 UT.0.0.15 1
38 S2 056067201 VU.0.0.2 1
39 SR1 057093014 UT.0.16 1
39 SR1 057093017 VU.0.5 1
40 MT 028021430 UT.7 1
40 MT 028021428 VU.4 1
41 Z1 028038042 UT.8 1
41 Z1 057110002 VU.1 1
42 OPTIONAL 057095010 VS.0.19 1 1
43 056020029 MM.3.0.2 1 1
44 S1 056067157 MQ.0.0.1 1 1
45 056072062 QF.0.0.10 1 1
46 756005012 FU.1.6.1 1 1
47 000097922 BP.2.0.20 2 2
48 057052019 QF.0.13 1 1
49 057094033 UQ.0.3 1

Dwg 201 241

40

34

Qty.

35

39

OM-188 414 Page 14

Effective January 1, 2000

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

LIMITED W ARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin,
warrants to its original retail purchaser that new Miller
equipment sold after the effective date of this limited warranty
is free of defects in material and workmanship at the time it is
shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser,
or one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to
an International distributor.

1. 5 Years Parts – 3 Years Labor
* Original main power rectifiers
* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Supplies
* Intellitig
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the
engine manufacturer.)

3. 1 Year — Parts and Labor
* DS-2 Feeder
* Motor Driven Guns (w/exception of Spoolmate 185

and Spoolmate 250)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* IHPS Power Sources
* Water Coolant Systems
* HF Units
* Grids
* Maxstar 140
* Spot Welders
* Load Banks
* Miller Cyclomatic Equipment
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field o p t i o n s a r e c o v e r e d u n d e r True Blue

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts
* MIG Guns/TIG Torches
* Induction heating coils and blankets

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches
* Remote Controls
* Accessory Kits
* Replacement Parts (No labor)
* Spoolmate 185 and Spoolmate 250

Miller’s True Blue Limited Warranty shall not apply to:

1. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.

2. Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.

3. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the
goods at customer’s risk and expense. Miller’s option of
repair or replacement will be F.O.B., Factory at Appleton,
Wisconsin, or F.O.B. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERA TION O F L AW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
AND DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated
herein, and to the extent that they may not be waived, the
limitations and exclusions set out above may not apply. This
Limited Warranty provides specific legal rights, and other
rights may be available, but may vary from province to
province.

milan_warr 4/00

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

PRINTED IN USA  2000 Miller Electric Mfg. Co. 1/00

Miller Electric Mfg. Co.

An Ill inoi s Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters–USA

Phone: [phone]
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters –
United Kingdom

Phone: [phone]
FAX: [phone]

Miller Europe
Italy

Phone: [phone]