Miller Electric INTEGRA 201/241 User's Manual
Contents
1. 18 in 457 mm for airflow GND PE a GND PE Connect First b L2 D ST 801 721 2 9 Installing Work Clamp 1 Wire Feeder Connection 2 Work Connect 3 Negative Power Source Terminal 4 Positive Power Source Terminal OM 188 414 Page 8 SECTION 3 OPERATION 3 1 Controls Handle Wire Speed Control Pilot Light Spot Timer Optional Amperage and Volt meter Power Switch Thermal Overload Pilot Light 10 Position Voltage Control Torch Connector 0 R O N O ON 0 NDIDNNNNNNNNN UU LULU LD LDUUULOD NDIDNNNNNNNNN UU LU ULUDLDUUULO OM 188 414 Page 9 SECTION 4 MAINTENANCE AND TROUBLESHOOTING 4 1 Routine Maintenance e gt gt 0 A Disconnect power before maintaining 3 Months Replace unreadable labels Ol EA Repair or replace ONN R Ss S cracked weld cable AN Ra ar all 6 Clean and tighten weld terminals A 4 6 Months Blow out or vacuum inside during heavy service clean monthly 4 2 Circuit Breaker CB1 o ap JA 1 Circuit Breaker CB1 I2. 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 suss 9 9 1 Controls nef pve eternal et n es Ma da a 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 zi tei win ernie ne 13 WARRANTY Declaration of Conformity Manufactruer s Name MILLER Europe S P A Manufacturer s Address Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Declares that this product NT E G R A 2 01 2 4 1 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 Requi
3. 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
4. CE C Visit our website at www MillerWelds com OM 188 414C January 2000 Effective with serial number 165 748 EH i er Processes MNM MIG GMAW Welding The P ower of Blue Flux Cored FCAW Welding Description 2 E EN Arc Welding Power Source and Wire Feeder INTEGRA 201 241 OWNER S MANUAL 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 Troubleshoo
5. NN Dia Item Ref 11 12 13 14 15 16 17 18 Code 156012109 116121100 156034001 057014063 056054055 156002018 116122285 116123001 Dwg UV 0 0 21 UV 0 0 15 BP 2 0 19 UV 0 7 QF 5 0 2 QF 0 0 13 UV 0 0 16 DU 0 0 6 OM 188 414 Page 13 6 2 Main Assembly Item 0 NOO BB HR PB BB PB PB ON AH O 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Dia Ref OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL Code 056052033 156019694 156019672 156053040 156053036 156053037 156053038 156053041 156053042 156053043 156076072 556090033 156076073 656064001 156009112 156032112 056018001 156019671 156017053 156017054 057010048 056092039 000046432 156018033 156009079 156022064 156009075 000010191 000058628 656102001 OM 188 414 Page 14 Dwg MD 4 0 1 FZ 0 9 1 MD 4 0 6 DIA 0 6 V DIA 0 8 V DIA 1 0 V DIA 1 2 V DIA 1 2 K DIA 1 0 U DIA 1 2 U MD 4 0 5 MD 5 0 1 MD 4 2 7 MD 4 2 5 MD 4 2 4 MD 4 2 3 MD 4 2 2 MD 4 2 1 MD 4 3 1 MD 4 3 2 QF 0 23 FZ 4 0 5 OL 0 0 14 GF 1 0 4 GF 1 0 2 FU 1 0 6 FU 1 0 7 BH 0 0 3 Qty 201 241 1 3 4 1 1 1 1 1 4 4 4 A 4 A 4 4 4 4 4 4 4 4 4 4 A 4 4 2 1 DR S O O O niin nin Aa a i ign Item 25 26 27 28 29 30 31 32 32 33 34 35 36 37 38 38 39 39 40 40 41 41 42 43 44 45 46 47 48 49 Dia Ref CB PC W W T2 FM GS
6. Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under 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 amp 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 eguipment that has been improperly installed improperly operated or misused based upon industry standards or eguipment which has not had reasonable and necessary maintenance or eguipment which has been used for operation outside of the specifications for the eguipment 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 EOUIPMENT In the event of a warranty claim covered by this warra
7. S2 S2 SR1 SR1 MT MT Zi Zi OPTIONAL S1 Code 116009041 056067188 028061049 056076152 057014065 027061016 057014063 057079026 057079027 056091041 058021081 056126062 056082091 056061042 056067189 056067201 057093014 057093017 028021430 028021428 028038042 057110002 057095010 056020029 056067157 056072062 756005012 000097922 057052019 057094033 Dwg CV 0 0 2 UV 0 0 9 QF 6 DD 0 0 7 UT 0 21 QF 0 21 UV 0 7 QF 0 20 UV 0 12 QF 0 0 12 QF 7 UR 0 0 7 VU 0 0 4 UV 0 0 7 UT 0 0 15 VU 0 0 2 UT 0 16 VU 0 5 UT 7 VU 4 UT 8 VU 1 VS 0 19 MM 3 0 2 MQ 0 0 1 QF 0 0 10 FU 1 6 1 BP 2 0 20 QF 0 13 UQ 0 3 Qty 201 241 mn 1 lt N 4 PRN A lt 2 N lt lt annua 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 WARRANTY 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
8. T can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit oe f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit n SDA OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Ao Reduce current or reduce duty cycle before starting to weld again e Donotblock or filter airflow to unit v STATIC ESD can damage PC boards P e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards N N MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e 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 Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances Ameri
9. ate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e 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 e 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 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 e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards e Wear approved sa
10. can 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 Protec tion Association Batterymarch Park Guincy MA 02269 dB MOVING PARTS can cause injury e Keep away from moving parts such as fans x e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications eguipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e If notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained 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 e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and d
11. f CB1 opens wire feeding stops S 2 Drive Roll Assembly 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 see Section 2 2 An overload condition occurred Release gun trigger see Section 4 3 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 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 contro
12. f evidence in the committees 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 OM 188 414 Page 4 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 opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 2 INSTALLATION 2 1 Specifications Rated Input Amperage at Rated Rated Output Output NN Max Open E Model 100 60 20 Circuit Voltage 230 V Dimension mm Weight kg 90A 116A 200A 26A 201 18 5 V 20V 24V 38 2A 310 x 540 x 957 70 115A 150 A 240 A 35A 241 20 V 21V 26V 41 2 5A 310 x 540 x 957 80 Wire feed speed range 1 8 mpm to 18 mpm While idling 2 2 D
13. fety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection WELDING can cause fire or explosion ja 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 workpiece and hot eguipment can cause fires and 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 e Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e 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 e Connect work cable to the work as close to the welding area as prac
14. 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 Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance Ki FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNI
15. l board Poor weld bead or welding wire is noodle welding Check polarity setting for type of welding wire being used OM 188 414 Page 11 SECTION 5 ELECTRICAL DIAGRAM 5 1 INTEGRA 201 cod 956 142 275 GAS I lt bes o 32 lt lt BLACK NERO oOo 11011 0 ALL p H s iL T ROSSO L G W s AN RED N RECT 2 3 lt lt 5 2 INTEGRA 241 ii cod 956 142 211 2 S 2 3 w 5 6 L o 7 8 9 D w N o gt _ 400 V amp 10 E 0 ov OM 188 414 Page 12 SECTION 6 PARTS LIST 6 1 Item O J O FP ND a o Common Parts Assembly Dia Ref Code 000151187 116122284 156087017 156009067 056054064 116005165 150005001 156011002 116005316 Dwg PV 0 0 18 UV 0 0 14 VS 0 0 13 DZ 0 0 25 UV 0 0 17 ND D
16. l housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e 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 e Properly install and ground this equipment according to its Owners Manual and national state and local codes e 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 e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cab
17. les Do not drape cables over your body som nd 4 98 e s PA vi 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 e If earth grounding of the workpiece is required ground it directly with a separate cable e Donottouch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e 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 e 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 Keep your head out of the fumes Do not breathe the fumes If inside ventil
18. nty 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 OPERATION OF LAW 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 no
19. ow rate is 20 cfh cubic feet per hour Check wire man ufacturers recommended flow rate This flow gauge can be adjusted between 5 and 25 cfh Ref ST 148 265 B Ref ST 149 827 B Ref ST 158 697 A OM 188 414 Page 6 2 5 Installing Drive Roll and Wire Inlet Guide 1 Securing Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touch ing Tighten screw 3 Wire Tension 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 2 6 Installing Wire Spool and Adjusting Hub Tension When a slight force is needed to turn spool tension is set Tools Needed ee I 15 16in ST 072573 B 2 7 Electrical Service Guide 201 241 Input Voltage 230 230 Input Amperes at Rated Output 26 35 Max Recommended Standard Fuse or Circuit Breaker Rating in Amperes 26 35 Input Conductor Size in mm 4 4 Grounding Conductor Size in mm2 4 4 Power cord supplied with the unit is sized for 230V operation Larger power cord may be required for cable lengths greater than 3 meters C onsult national and local regulations OM 188 414 Page 7 2 8 Selecting a Location and Connecting Input Power Have only qualified persons make this installation 1 Rating Label Supply correct input power
20. own low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual o f 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 Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body o
21. rements 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 39 0 2 982901 Fax 39 0 2 98290 203 dec_con 5 97 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage A Marks a special safety message Means Warning Watch Out There are possible hazards With this procedure The possible hazards are shown in the adjoining symbols 5 Means Note not safety related 1 2 Arc Welding Hazards A 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 A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away 3 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 rol
22. t 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 Purchase Date Distributor Address PRINTED IN USA Serial Style Number Date which equipment was delivered to original customer 2000 Miller Electric Mfg Co 1 00 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA Phone 414 735 4505 USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 Miller Europe Italy Phone 39 0 2982901 Miller The Power of Blue
23. tical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding IN FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 188 414 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away 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 e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain
24. ting 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 PRUEBE JA AIHA 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 eguipment For information on other guality Miller products contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets Miller The Power of Blue 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 To EMF Informations za bi a Aa ee ake A Ta 4 SECTION 2 INSTALLATION 5 2 1 SPECiiCA ONS xs din siege na ha rd un na nn 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
25. uty Cycle and Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating 300 If unit overheats thermostat s opens output stops and cooling 250 fan runs Wait fifteen minutes for unit to cool Reduce amperage or n voltage or duty cycle before 5 A 200 welding a A Exceeding duty cycle can damage unit and void 6 warranty 150 a l uu 241 100 90 201 80 20 30 40 50 60 70 80 90 100 60 Duty Cycle at 200 Amperes m 6 Minutes Welding 4 Minutes Resting DUTY CYCLE 40 Duty Cycle at 250 Amperes 4 Minutes Welding 255 020 6 Minutes Resting Overheating pet n b gt 6 gt D Minutes 0 AorV Reduce Duty Cycle M duty1 4 95 SB 150 215 OM 188 414 Page 5 2 3 Volt Ampere Curves 50 40 Model 201 VOLTS 8 VOLTS 8 Model 241 1 Normal Volt Ampere Curves The volt ampere curves show the normal minimum and maximum voltage and amperage output capa bilities of the welding power source Curves of other settings fall be tween the curves shown dwg 802004 802003 2 4 Installing Gas Supply Chain gas cylinder to running gear wall or other stationary support so cylinder cannot fall and break off valve 1 Regulator Flow Gauge Install so face is vertical 2 Gas Hose Connection 3 Flow Adjust Typical fl
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