Miller | MD026806D | Owner Manual | Miller MIGMATIC 220 BASE/DX User manual

Miller MIGMATIC 220 BASE/DX User manual
OM-246 691D
2013−01
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
Wire Feeder
R
MigMatic 220/250 Base/DX
CE
Visit our website at
www.MillerWelds.com
OWNER’S MANUAL
File: MIG (GMAW)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
7
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
3-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. IP Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
3-4. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
9
3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
10
3-8. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Positioning Jumper Links (230/400V 3-Phase Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
3-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Selecting a Location and Connecting Input Power (1-Phase and 3-Phase) . . . . . . . . . . . . . . . . . . . . .
3-12. Installing Drive Rolls And Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
14
16
3-13. Threading Welding Wire And Adjusting Pressure Roll Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
18
4-1. Controls For MigMatic 220/250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Burnback And Spot Weld Timer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
18
4-3. Controls For MigMatic 220 DX / 250 DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Burnback And Spot Weld Timer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19
4-5. Welding Power Source Input Line Voltage Adjustment (DX Models Only) . . . . . . . . . . . . . . . . . . . . . .
4-6. Welding Power Source Setup Menu (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
21
4-7. Trigger Mode Selection (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Spool Gun Mode (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Welding Wire Diameter Selection For Synergic MIG (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . .
22
22
23
4-10. Welding Wire Type Selection For Synergic MIG (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Gas Selection For Synergic MIG (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
23
4-12. Selecting Manual MIG Welding (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Selecting Synergic MIG Welding (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
25
SECTION 5 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
26
5-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Unit Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
26
5-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
28
32
WARRANTY
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
MIGMATIC 220 DX, 230VAC
MIGMATIC 250 230/400VAC
MIGMATIC 250 DX, 230/400VAC
029015520
029015521
029015524
029015525
Council Directives:

2006/95/EC Low Voltage

2004/108/EC Electromagnetic Compatibility

2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:

IEC 60974­1 Arc Welding Equipment ­ Welding Power Sources: edition 3, 2005­07.

IEC 60974­5 Arc Welding Equipment – Wire Feeders: edition 2, 2007­11.

IEC 60974­10 Arc Welding Equipment ­ Electromagnetic Compatibility Requirements: edition 2.0, 2007­08.

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
(0Hz­300Hz)
EU Signatory:
January 2nd , 2013
___________________________________________________________________________________
Massimigliano Lavarini
Date of Declaration
ELECTRONIC ENGINEER R&D TECH. SUPPORT
956 172 015
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−10
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
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.
. 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.
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.
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 conductor 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.
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 following 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, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
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 machines 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. Disconnect cable for process not in
use.
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 equipment.
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
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 operations. 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.
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
workpiece, and hot equipment 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.
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 containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (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
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 bypass 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.
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, mechanical 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 number 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.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
BATTERY EXPLOSION can injure.
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.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
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.
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.
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.
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
D
D
D
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.
ARC WELDING can cause interference.
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.
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.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at 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.
D
D
D
D
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.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
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
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.)
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,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased 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 Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
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, 14501 George Carter Way, Suite
103, 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,
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 Industry, 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).
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, restrict access for passers−by or conduct 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.
OM-246 691 Page 4
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.
SECTION 2 − DEFINITIONS
2-1. Additional Safety Symbols And Definitions
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not remove or paint over (cover) the label.
Safe20 2012−05
OM-246 691 Page 5
Do not weld on drums or any closed containers.
Safe16 2012−05
Do not discard product (where applicable) 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.
Safe37 2012−05
Disconnect input plug or power before working on machine.
Safe30 2012−05
Read Owner’s Manual and inside labels for connection points and procedures.
ÍÍ
ÍÍ
?
?
Safe67 2012−06
V
A
Consult rating label for input power requirements.
Safe34 2012−05
Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.
Safe33 2012−05
<10
Falling unit can cause injury. Do not move or operate unit where it could tip.
Safe53 2012−05
3
1
Move jumper links as shown on inside label to match input voltage at
job site. Include extra length in grounding conductor and connect
grounding conductor first. Connect line input conductors as shown on
inside label. Double-check all connections, jumper link positions, and
input voltage before applying power.
Safe49 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
OM-246 691 Page 6
2-2. Miscellaneous Symbols And Definitions
A
U1
I2
IP
V
Volts
Alternating Current
(AC)
Direct Current
(DC)
Remote
On
Off
Protective Earth
(Ground)
Line Connection
Three Phase
Single Phase
Gas Metal Arc
Welding (GMAW)
Amperes
I1eff
U2
Primary Voltage
I1max
Rated Maximum
Supply Current
Rated Welding
Current
X
Duty Cycle
Percent
Degree Of
Protection
Circuit Breaker
Three Phase
Transformer
Rectifier
Two-Step Trigger
Operation
Four-Step Trigger
Operation
Gas Input
Gas Output
Gas Type
Voltage Input
Wire Feed Spool
Gun
Wire Feed
Read Operator’s
Manual
Wire Type
Diameter
Wire Burnback
Control
Wire Run-In Speed
Control
Maximum Effective
Supply Current
Conventional Load
Voltage
U0
Rated No Load
Voltage (Average)
Hz
Hertz
t
Spot Weld Time
OM-246 691 Page 7
SECTION 3 − INSTALLATION
3-1. Important Information Regarding CE Products (Sold Within The EU)
A. Information On Electromagnetic Fields (EMF)
!
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
S
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
B. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
!
This equipment does not comply with IEC 61000−3−12. If it is connected to a public low voltage system, it is the responsibility of
the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment can be connected.
ce-emc 2 2011-09
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. IP Rating
IP Rating: 23S. This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless
sheltered.
Operating Temperature Range: 14 F (-10 C) to 104 F (40C). Ratings were developed at an ambient temperature of 20 C to 25 C.
3-4. Specifications
Rated Output
Model
100%
60%
20%
220
230 VAC 50/60
Hz
90 A
18.5 V
116 A
19.8 V
200 A
24.0 V
Max. Open
Circuit
Voltage
Amperage
Range
DC
Dimension (mm)
Weight
(kg)
40.2
30-200 A
480 x 712 x 920
66 Net
Dimension (mm)
Weight
(kg)
480 x 712 x 920
73 Net
Wire feed speed range 1.3 mpm to 20 mpm.
Rated Output
Model
100%
60%
35%
250
230/400 VAC
50/60 Hz
145 A
21.0 V
190 A
23.0 V
250 A
26.5 V
Wire feed speed range 1.3 mpm to 20 mpm.
OM-246 691 Page 8
Max. Open
Circuit
Voltage
Amperage
Range
DC
43.0 V
30-250 A
IP
Rati
ng
IP23
S
3-5. Duty Cycle And Overheating
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.
% DUTY CYCLE
35% Duty Cycle At 250 Amperes
3-1/2 Minutes Welding
100% Duty Cycle At 145 Amperes
6-1/2 Minutes Resting
Continuous Welding
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
sduty1 5/95
3-6. 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.
Model 250
Model 220
MAX
MIN
OM-246 691 Page 9
3-7. 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
3
1
Argon Gas
Gas Hose Connection
Flow Adjust
Typical flow rate is 0.9 liters per
minute. Check wire manufacturer’s recommended flow rate. This
flow gauge can be adjusted between 2.36 and 11.8 liters per minute.
OR
2
3
CO2 Gas
Ref. ST-148 265-B / Ref. ST-149 827-B / Ref. ST-158 697-A
OM-246 691 Page 10
3-8. Installing Wire Spool And Adjusting Hub Tension
1
Spacers
Use only for 5Kg spool.
Hub Assembly
1
15 Kg Wire Spool
Assembly
5 Kg Wire Spool
Assembly
Tools Needed:
Ref. D2
OM-246 691 Page 11
3-9. Positioning Jumper Links (230/400V 3-Phase Models)
!
Disconnect and lockout/tagout 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.
400 Volts
400 Volts
230 Volts
230 Volts
956142718_3-5
OM-246 691 Page 12
3-10. 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
220
50/60 Hz Single Phase
250
50/60 Hz Three Phase
Input Voltage (V)
230
230
400
Input Amperes (A) At Rated Output
34
28
16
Time-Delay Fuses 2
40
30
15
3
50
40
25
10 (8)
6 (10)
4 (12)
Max Recommended Input Conductor Length In Meters (Feet)
41
(134)
38
(124)
69
(226)
Min Grounding Conductor Size In mm2 (AWG) 4
6 (10)
6 (10)
4 (12)
Max Recommended Standard Fuse Rating In Amperes1
Normal Operating Fuses
Min Input Conductor Size In mm2
(AWG) 4
Reference: 2011 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
310.15(B)(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.
Notes
OM-246 691 Page 13
3-11. Selecting a Location and Connecting Input Power (1-Phase and 3-Phase)
A. 1-Phase
1
5
=GND/PE
Earth Ground
7
Installation must meet all National
and Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input 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.
See rating label on unit and check input
voltage available at site.
4
18 in (457 mm)
for airflow
!
1
6
2
L1
L2
2
1
3
4
5
3
6
Black And White Input Conductor
(L1 And L2)
Green Or Green/Yellow Grounding
Conductor
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
Disconnect Device Grounding
Terminal
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 3-10 (fused disconnect switch shown).
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed:
Ref. D4
OM-246 691 Page 14
B. 3-Phase
3
= GND/PE
Earth Ground
!
Installation must meet all National
and Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input 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.
4
See rating label on unit and check input
voltage available at site.
For Three-Phase Operation
7
1
2
3
2
4
5
6
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
Green Or Green/Yellow Grounding
Conductor
Disconnect Device Grounding
Terminal
Input Conductors (L1, L2 And L3)
Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
L1
3
L2
L3
6
1
5
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 3-10 (fused disconnect switch shown).
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed:
Ref. D5
OM-246 691 Page 15
3-12. Installing Drive Rolls And Wire Guide
1
2
Inlet Wire Guide Securing
Screw
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 different 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.
2
4
Drive Roll Securing Screw
Tighten screw to secure drive roll.
1
3
4
Tools Needed:
2.5 mm
956142721_2-2
Notes
OM-246 691 Page 16
3-13. Threading Welding Wire And Adjusting Pressure Roll Tension
1
2
3
4
5
6
7
4
Wire Spool
Welding Wire
Inlet Wire Guide
Pressure Adjustment Knob
Drive Roll
Outlet Wire Guide
Gun Conduit Cable
Lay gun cable out straight.
7
1
Tools Needed:
2
3
5
6
. Hold wire tightly to keep it
from unraveling.
150 mm
(6 in.)
Open pressure assembly.
Pull and hold wire; cut off end.
. Use pressure indicator
Tighten
scale to set a desired
drive roll pressure.
1
2
3
4
Close and tighten pressure
assembly, and let go of wire.
Push wire thru guides into gun;
continue to hold wire.
Pressure
Indicator
Scale
Remove gun nozzle and contact tip.
Turn On.
Tighten
WOOD
Press gun trigger until wire
comes out of gun. Reinstall
contact tip and nozzle
1
2
3
4
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
OM-246 691 Page 17
SECTION 4 − OPERATION
4-1. Controls For MigMatic 220/250
1
Power Switch S1
Use switch to turn power on and off.
2
4
3
3
4
5
Voltage Control S2
Turn control clockwise to increase
voltage.
2
5
High Temperature Shutdown
Light PL2 (Orange LED)
Power Indicator Light PL1
(White LED)
Wire Feed Speed Control R1
Turn control clockwise to increase
wire feed speed.
1
6
MIG Torch Connection
Connection for Euro style MIG gun.
7
6
Work Lead Connection
7
956142715_5-5
4-2. Burnback And Spot Weld Timer Controls
1
Burnback Control R3
Time that welding wire stays energized after trigger is released.
1
2
2
Spot Weld Timer R2
Time that welding arc is active before shutting off automatically.
Spot Timer resets after releasing
gun trigger.
956142715_3-5
OM-246 691 Page 18
4-3. Controls For MigMatic 220 DX / 250 DX
1
Power Switch S1
Use switch to turn power on and off.
2
4
9
Turn control clockwise to increase voltage.
3
3
4
2
5
10
5
1
6
6
High Temperature Shutdown Light
PL2-(Orange LED)
Power Indicator Light PL1 (White
LED)
Wire Feed Speed (WFS)/Trim (Arc
Length) And Line Input Adjustment
Control R1 (See Section 4-5)
MIG Torch Connection
Connection for Euro style MIG gun.
8
11
12
Voltage Control S2
7
8
14
13
9
7
Work Lead Connection
Spool Gun Connection 7-pin Plug
Receptacle
Digital Display Meter
Displays values and parameters for selected 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 synergic 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
1
1
2
Burnback Control R3
Use control to set time welding wire
stays energized after trigger is released.
2
Wire Run-In Speed Control
R2
Use control to determine rate at
which welding wire feeds before an
arc is initiated.
956142718_4-5
OM-246 691 Page 19
4-5. Welding Power Source Input Line Voltage Adjustment (DX Models Only)
1
2
3
3
4
2
4
Wire Feed Speed (WFS)/Trim
(Arc Length) And Line Input
Adjustment Control R1
Wire Feed Speed Indicator
Scale (Manual Mode)
Input Line Voltage Adjustment
Center Indicator (Synergic
Mode)
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.
1
6
7
9
8
5
6
The required type of input voltage
correction (plus or minus) is displayed on digital meter as follows:
7
5
Power Indicator Light PL1
Digital Meter Display
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 machine 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 20
4-6. Welding Power Source Setup Menu (DX Models Only)
1
2
1
3
4
5 6
7
8
9
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
10
speed is meters per minute. To
change to inches per minute,
press and hold setup and trigger function buttons for approximately 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 21
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.
1
2
2
When trigger is pressed, welding starts.
When trigger is released, welding continues. When trigger is pressed and released
a second time, welding stops.
4
3
3
4T Trigger Mode
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)
1
Spool Gun Mode Indicator LED
4-8. Spool Gun Mode (DX Models Only)
Connect spool gun to 7-pin spool gun receptacle (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.
1
. 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 22
4-9. Welding Wire Diameter Selection For Synergic MIG (DX Models Only)
1
2
Welding Wire Diameters
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.
1
2
4-10. Welding Wire Type Selection For Synergic MIG (DX Models Only)
1
2
Welding Wire Types
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.
1
2
4-11. Gas Selection For Synergic MIG (DX Models Only)
1
2
Shielding Gas Types
Gas Selection Button
Press button to select desired
shielding gas type: CO2 (Carbon
Dioxide), Mix (ArCO2), Arg (Argon),
and lite corresponding LED.
1
2
OM-246 691 Page 23
4-12. Selecting Manual MIG Welding (DX Models Only)
1
2
4
5
1
2
3
Setup Button
Manual MIG Mode Indicator
Press and hold setup button for approximately 3 seconds to select
manual MIG mode and lite indicator.
3
4
5
Voltage Control S2
Wire Feed Speed (WFS)/Trim
(Arc Length) And Line Input
Adjustment Control R1
Digital Display Meter
. In Manual MIG mode, the operator 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 %).
6
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 operation, see section 4-8.
OM-246 691 Page 24
4-13. Selecting Synergic MIG Welding (DX Models Only)
1
2
4
2
5
1
3
Setup Button
Synergic MIG Mode Indicator
Press and hold Setup button for approximately 3 seconds to select synergic MIG mode and lite indicator.
3
4
5
Voltage Control S2
Wire Feed Speed (WFS)/Trim
(Arc Length) And Line Input
Adjustment Control R1
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 %).
10
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
6
7
8
9
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 shielding gas.
Spool Gun Operation:
10 Spool Gun Receptacle
For spool gun connection and operation, see section 4-8.
OM-246 691 Page 25
SECTION 5 − MAINTENANCE &TROUBLESHOOTING
5-1. Routine Maintenance
!
. Maintain more often
Disconnect power
before maintaining.
during severe conditions.
3 Months
Replace unreadable labels
Repair or replace
cracked weld cable
Clean and tighten weld terminals
6 Months
Remove drive roll and
carrier. Apply light coat
of oil or grease to drive
motor shaft.
Blow out or vacuum inside.
OR
5-2. Circuit Breaker CB1
1
Circuit Breaker CB1
CB1 protects the unit from overloading of drive motor M1. If CB1
opens, wire feeding stops.
1
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.
2
Allow cooling period and reset
breaker. Close door.
3
5-3. Unit Overload
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 26
5-4. Troubleshooting
Trouble
Remedy
No weld output; wire does not feed.
Be sure line disconnect switch is On (see Section 3-11).
Replace building line fuse or reset circuit breaker if open (see Section 3-11).
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.
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.
Low weld output.
Connect unit to proper input voltage or check for low line voltage (see Section 3-9).
Check input voltage jumper links and correct position if necessary (see Section 3-9).
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).
Low, high, or erratic wire speed.
Readjust front panel settings (see Section 4-1).
Change to correct size drive rolls.
Readjust drive roll pressure (see Section 3-13).
Replace inlet guide, contact tip, and/or liner if necessary.
Check position of input jumper links (see Section 3-9).
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.
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).
OM-246 691 Page 27
SECTION 6 − ELECTRICAL DIAGRAMS
956142709-C
Figure 6-1. Circuit Diagram for Migmatic 220 (230 VAC)
OM-246 691 Page 28
956142710-B
Figure 6-2. Circuit Diagram for Migmatic 250 (230/400 VAC)
OM-246 691 Page 29
956142711-F
Figure 6-3. Circuit Diagram for Migmatic 220 DX (230 VAC)
OM-246 691 Page 30
956142712-E
Figure 6-4. Circuit Diagram for Migmatic 250 DX (230/400 VAC)
OM-246 691 Page 31
14
15
16
19
20
17
18
21
13
21
1
2
12
3
4
11
7
10
5
6
19
9
10
8
SECTION 7 − PARTS LIST
956142718_2-5-A
Figure 7-1. Wrapper Assembly, All Models
OM-246 691 Page 32
Item
No.
Part
No.
Description
Figure 7-1. Wrapper Assembly, All Models
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
6
6
6
7
8
9
10
11
12
13
14
15
16
17
18
18
19
20
21
. . . . . . . 156034005
. . . . . . . 156007042
. . . . . . . 156034006
. . . . . . . 156005145
. . . . . . . 000207235
. . . . . . . 956142682
. . . . . . . 956142684
. . . . . . . 956142683
. . . . . . . 956142685
. . . . . . . 000207291
. . . . . . . 156023157
. . . . . . . 056 054082
. . . . . . . 156009132
. . . . . . . 156012137
. . . . . . +156122080
. . . . . . . 056054083
. . . . . . . 356029212
. . . . . . . 156118060
. . . . . . . 656002019
. . . . . . . 156118061
. . . . . . . 356029210
. . . . . . . 356029209
. . . . . . . 000207233
. . . . . . +156122081
. . . . . . . 156009137
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Quantity
Base
Catch, side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Panel, hinged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Rack, upper support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, warning, tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rating Plate, MigMatic 220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rating Plate, MigMatic 220 DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rating Plate, MigMatic 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rating Plate, MigMatic 250 DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, primary power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel, retaining clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel, rear, 200 O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle, rear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel/Caster, front 80 O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, lower, front, MigMatic 220/250 . . . . . . . . . . . . . . . . . . . . . .
Plastic, lower, front, MigMatic 220/250 . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plastic, upper, front, MigMatic 220/250 . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, upper, front, MigMatic 220/250 . . . . . . . . . . . . . . . . . . . . . .
Nameplate, upper, front, MigMatic 220 DX/250 DX . . . . . . . . . . . . . . .
Label, general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Panel, left side, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, D. 12 x 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
1
1
2
2
4
1
1
2
1
1
1
1
1
1
2
1
2
DX
....... 1
....... 1
....... 2
....... 1
....... 1
.........
....... 1
.........
....... 1
....... 1
....... 2
....... 2
....... 4
....... 1
....... 1
....... 2
....... 1
....... 1
....... 1
....... 1
.........
....... 1
....... 2
....... 1
....... 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
Figure 7-2. Main Assembly for MigMatic 220
OM-246 691 Page 34
24
23
19
25
20
21
22
956142716
18
14
13
12
26
27
28
29
30
11 10
9
8
6
45
31
7
4
32
33
35
5
34
36
3
1
38
46
37
2
47
48
39
49
40
50
51
41
52
53
42
43
44
54
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.
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 35
956142719-A
Figure 7-3. Main Assembly for MigMatic 220 DX
OM-246 691 Page 36
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 7-3. Main Assembly for MigMatic 220 DX
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. . . . . . . . . . . 156 012 138
. . . . . . . . . . . 656 009 004
. . . . . . . . . . . 656 102 007
. . . . . . . . . . . 156 009 134
. . . . . . . . . . . 156 032 136
. . . . . . . . . . . 056 020 072
. . . . . . . . . . . 156 015 027
. . . . . . F1 . *056 092 097
. . . . . . . . . . . 000 207 076
. . . . . . . . . . . 356 029 213
. . . . . . . . . . . 156 008 040
. . . . . . . . . . . 057 021 023
. . . . . . . . . . . 556 090 042
. . . . . . . . . . . 057 052 047
. . . . . . . . . . . 956 142 714
. . . . . . . . . . . 116 039 030
. . . . . PC2 . 057 084 143
. . . . . . S2 . 056 067 270
. . . . . R1 . 056 059 284
. . . . . . . . . . . 000 207 075
. . . . . RC1 . 056 076 261
. . . . . . . . . . . 056 020 069
. . . . . . . . . . . 156 118 066
. . . . . . S1 . 056 067 267
. . . . . . . . . . . 056 076 260
. . . . . HD1 . 056 167 007
. . . . . . T1 . . 058 021 146
. . . . . . Z . . 057 098 018
. . . . . R4 . 056 059 285
. . . . . . . . . . . 000 178 937
. . . . . . . . . . +156 122 082
. . . . . SR1 . 056 050 156
. . . . . TP1 . 056 159 028
. . . . . . . . . . . 656 026 123
. . . . . . . . . . . 156 005 146
. . . . . PC3 . 057 084 144
. . . . . . . . . . . 056 092 098
. . . . . PC1 . 057 084 145
. . . . . . T2 . . 058 021 147
. . . . . C1 . 056 082 100
. . . . . . . . . . . 056 070 041
. . . . . . W . . 057 079 036
. . . . . . . . . . . 156 005 147
. . . . . . . . . . . 000 155 436
. . . . . . . . . . . 156 118 063
. . . . . FM . 057 035 019
. . . . . . . . . . . 156 118 065
. . . . . . . . . . . 000 176 106
. . . . . GSV . 056 061 068
. . . . . . . . . . . 356 029 215
. . . . . . . . . . . . . . . 220 805
. . . . . . . . . . . 656 089 041
. . . . . . . . . . . 256 071 010
. . . . C3, C4 056 082 102
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Spool Holder, shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, 17x70, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer , flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, 17x3x6 L.40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handwheel Reel, W/Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spool Nut, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse, 2A 5 0 0 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, pointer, d.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, inner, MigMatic 250 DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer, wire feeder, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Drive System, 2 roll, d.48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Guide, outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, minieuro, quick female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, box consumable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Box Protection, pcb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board, digital volt/amp/wire speed display . . . . . . . . . . . . . . . . . . .
Switch, 25A 10 pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potentiometer, 1 Kohms, linear, straight pins . . . . . . . . . . . . . . . . . . . . . . .
Knob, pointer, d. 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle, 7pin, spool gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, pointer, d. 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, primary power on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dinse Socket, female, 50 mmq. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transducer, current 400A, module supply V+/−1 2 . . . . . . . . . . . . . . . . . .
Transformer, 230V, 60x80 Al. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choke, 230V, D.7, 340x60 Al. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistance, 3ohms, D.16 L 9 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier, PMS 20/4/2F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat, 100 1 0 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, gas, braided, black, D. 5x8, 10 bar . . . . . . . . . . . . . . . . . . . . . . . . .
Corner Seal, plastic, r. 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board, Burn Back Time slope adjustment . . . . . . . . . . . . . . . . . . .
Fuse Holder, 6.3A 2 5 0 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer, auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, 22000MF 63V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Contacts, BL/X2 N C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contactor, 24V 16A 4NA CN−1 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, support, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid, gas valve, 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, rear, input gas, MigMatic 220/250 . . . . . . . . . . . . . . . . . . . . .
Nut, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Cable, neoprene, mt 3x4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, MPW 0,1MF 10% 1000VCC . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2
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1
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1
1
1
1
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
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 37
Figure 7-4. Main Assembly for MigMatic 250
OM-246 691 Page 38
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956142717
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52
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43
53
41
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 7-4. Main Assembly for MigMatic 250
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. . . . . . . . . . . 156 012 138
. . . . . . . . . . . 656 009 004
. . . . . . . . . . . 656 102 007
. . . . . . . . . . . 156 009 134
. . . . . . . . . . . 156 032 136
. . . . . . . . . . . 056 020 072
. . . . . . . . . . . 156 015 027
. . . . . . F1 . *056 092 097
. . . . . . . . . . . 000 207 076
. . . . . . . . . . . 356 029 214
. . . . . . . . . . . 156 008 040
. . . . . . . . . . . 057 021 023
. . . . . . . . . . . 556 090 042
. . . . . . . . . . . 057 052 047
. . . . . . . . . . . 956 142 714
. . . . . . . . . . . 116 039 030
. . . . . . S2 . 056 067 269
. . . . . R1 . 056 059 284
. . . . . PL1 . 056 072 079
. . . . . PL2 . 056 072 080
. . . . . . . . . . . 000 207 075
. . . . . . . . . . . 056 020 069
. . . . . . . . . . . 156 118 062
. . . . . . S1 . 056 067 267
. . . . . . . . . . . 056 076 260
. . . . . . T1 . . 058 021 148
. . . . . . . . . . . 000 178 937
. . . . . . . . . . +156 122 082
. . . . . SR1 . 056 050 157
. . . . . TP1 . 056 059 288
. . . . . . . . . . . 656 026 123
. . . . . . . . . . . 156 005 146
. . . . . R2 . 056 059 286
. . . . . R3 . 056 059 287
. . . . . . . . . . . 056 092 098
. . . . . CB1 . 056 067 268
. . . . . PC1 . 057 084 142
. . . . . . T2 . . 058 021 147
. . . . . . . . . . . 057 024 026
. . . . . . . . . . . 556 070 017
. . . . . . . . . . . 116 014 052
. . . . . . W . . 057 079 036
. . . . . . . . . . . 156 005 147
. . . . . . . . . . . 000 155 436
. . . . . . . . . . . 156 118 063
. . . . . FM . 057 035 019
. . . . . . . . . . . 156 118 065
. . . . . . . . . . . 000 176 106
. . . . . GSV . 056 061 068
. . . . . . . . . . . 356 029 215
. . . . . . . . . . . . . . . 220 805
. . . . . . . . . . . 656 089 041
. . . . . . . . . . . 256 071 011
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Spool Holder, shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, 17x70, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer , flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, 17x3x6 L.40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handwheel Reel, W/Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spool Nut, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse, 2A 500V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, pointer, d.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, inner, MigMatic 220/250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer, wire feeder, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Drive System, 2 roll, d.48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Guide, outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, minieuro, quick female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, box consumable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Box Protection, pcb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, 20A SCH 9813 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potentiometer, 1Kohms, linear, straight pins . . . . . . . . . . . . . . . . . . . . . . .
Pilot, 24V lamp, white . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot, 24V lamp, orange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, pointer, d.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, pointer, d.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, primary power on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dinse Socket, female, 50 mmq. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer, 3ph 230/400V, 60x60x150 Al. . . . . . . . . . . . . . . . . . . . . . . . .
Label, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier, PTS 24/3/2F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat, 100  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, gas, braided, black, D. 5x8, 10 bar . . . . . . . . . . . . . . . . . . . . . . . . .
Corner Seal, plastic, r. 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potentiometer, 100 Kohms, W/Switch straight pins . . . . . . . . . . . . . . . . .
Potentiometer, 10 Kohms, linear, straight pins . . . . . . . . . . . . . . . . . . . . .
Fuse Holder, 6.3A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, 4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer, auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Power Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Link, primary power terminal board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protection, primary power terminal board . . . . . . . . . . . . . . . . . . . . . . . . . .
Contactor, 24V 16A 4NA CN−1 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, support, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid, gas valve, 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, rear, input gas, MigMatic 220/250 . . . . . . . . . . . . . . . . . . . . .
Nut, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Cable, neoprene, mt 4x2,5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
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1
2
1
1
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1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
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 39
956142720-A
Figure 7-5. Main Assembly for MigMatic 250 DX
OM-246 691 Page 40
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40
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 7-5. Main Assembly for MigMatic 250 DX
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. . . . . . . . . . . 156 012 138
. . . . . . . . . . . 656 009 004
. . . . . . . . . . . 656 102 007
. . . . . . . . . . . 156 009 134
. . . . . . . . . . . 156 032 136
. . . . . . . . . . . 056 020 072
. . . . . . . . . . . 156 015 027
. . . . . . F1 . *056 092 097
. . . . . . . . . . . 000 207 076
. . . . . . . . . . . 356 029 213
. . . . . . . . . . . 156 008 040
. . . . . . . . . . . 057 021 023
. . . . . . . . . . . 556 090 042
. . . . . . . . . . . 057 052 047
. . . . . . . . . . . 956 142 714
. . . . . . . . . . . 116 039 030
. . . . . PC2 . 057 084 143
. . . . . . S2 . 056 067 271
. . . . . R1 . 056 059 284
. . . . . . . . . . . 000 207 075
. . . . . RC1 . 056 076 261
. . . . . . . . . . . 056 020 069
. . . . . . . . . . . 156 118 066
. . . . . . S1 . 056 067 267
. . . . . . . . . . . 056 076 260
. . . . . HD1 . 056 167 007
. . . . . . T1 . . 058 021 148
. . . . . . . . . . . 000 178 937
. . . . . . . . . . +156 122 082
. . . . . SR1 . 056 050 157
. . . . . TP1 . 056 059 288
. . . . . . . . . . . 656 026 123
. . . . . . . . . . . 156 005 146
. . . . . PC3 . 057 084 144
. . . . . . . . . . . 056 092 098
. . . . . PC1 . 057 084 146
. . . . . . T2 . . 058 021 147
. . . . . . . . . . . 057 024 026
. . . . . . . . . . . 556 070 017
. . . . . . . . . . . 116 014 052
. . . . . . W . . 057 079 036
. . . . . . . . . . . 156 005 147
. . . . . . . . . . . 000 155 436
. . . . . . . . . . . 156 118 063
. . . . . . . . . . . 057 035 019
. . . . . . . . . . . 156 118 065
. . . . . . . . . . . 000 176 106
. . . . . GSV . 056 061 068
. . . . . . . . . . . 356 029 215
. . . . . . . . . . . . . . . 220 805
. . . . . . . . . . . 656 089 041
. . . . . . . . . . . 256 071 011
. . . . C1, C2 056 082 102
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Spool Holder, shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, 17x70, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer , flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, 17x3x6 L.40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handwheel Reel, W/Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spool Nut, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse, 2A 5 0 0 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, pointer, d.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, inner, MigMatic 250 DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer, wire feeder, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Drive System, 2 roll, d.48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Guide, outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, minieuro, quick female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, box consumable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Box Protection, pcb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board, digital volt/amp/wire feed display . . . . . . . . . . . . . . . . . . . .
Switch, 20A 10 pos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potentiometer, 1 Kohms, linear, straight pins . . . . . . . . . . . . . . . . . . . . . . .
Knob, pointer, d.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle, 7pin, spool gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, pointer, d.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, primary power on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dinse Socket, female, 50 mmq. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transducer, current 400A, module supply V+/−12 . . . . . . . . . . . . . . . . . .
Transformer, 3ph 230/400V, 60x60x150 Al. . . . . . . . . . . . . . . . . . . . . . . . .
Label, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier, PTS 24/3/2F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat, 100  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, gas, braided, black, D. 5x8, 10 bar . . . . . . . . . . . . . . . . . . . . . . . . .
Corner Seal, plastic, r. 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board, Burn Back Time slope adjustment . . . . . . . . . . . . . . . . . . .
Fuse Holder, 6.3A 2 5 0 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer, auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Power Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Link, primary power terminal board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protection, primary power terminal board . . . . . . . . . . . . . . . . . . . . . . . . . .
Contactor, 24V 16A 4NA CN−1 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, support, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid, gas valve, 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, rear, input gas, MigMatic 220/250 . . . . . . . . . . . . . . . . . . . . .
Nut, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Cable, neoprene, mt 4x2,5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, MPW 0,1MF 10% 1000VCC . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
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1
1
1
1
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2
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2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
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 41
40
39
2
1
38
2
14
37
5
4
36
6
7
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19
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13
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27
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30
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28
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33
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25
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22
956142721
Figure 7-6. Drive Assembly, Wire (2 Roll)
OM-246 691 Page 42
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-6. Drive Assembly, Wire (2 Roll)
1 . . . . . . . . . . . 056126079
2 . . . . . . . . . . . 156018121
3 . . . . . . . . . . . 556075032
4 . . . . . . . . . . . 156003034
5 . . . . . . . . . . . 156012140
6 . . . . . . . . . . . 156003035
7 . . . . . . . . . . . 156012142
8 . . . . . . . . . . . 656003014
9 . . . . . . . . . . . 156012141
10 . . . . . . . . . . 156023164
11 . . . . . . . . . . 156017161
12 . . . . . . . . . . 156012143
13 . . . . . . . . . . 156033035
14 . . . . . . . . . . 156019776
15 . . . . . . . . . . 156019777
16 . . . . . . . . . . 056002016
17 . . . . . . . . . . 156032132
18 . . . . . . . . . . 156012144
19 . . . . . . . . . . 756009061
20 . . . . . . . . . . 156012145
21 . . . . . . . . . . 156009136
22 . . . . . . . . . . 156053112
23 . . . . . . . . . . 156033036
24 . . . . . . . . . . 156013050
25 . . . . . . . . . . 156003036
26 . . . . . . . . . . 356052008
27 . . . . . . . . . . 156019778
28 . . . . . . . . . . 156023165
29 . . . . . . . . . . 156013051
30 . . . . . . . . . . 156003037
31 . . . . . . . . . . 156053109
32 . . . . . . . . . . 656021268
33 . . . . . . . . . . 656033010
34 . . . . . . . . . . 156019779
35 . . . . . . . . . *156090022
36 . . . . . . . . . . 656064003
37 . . . . . . . . . . 156032133
38 . . . . . . . . . . 156032134
39 . . . . . . . . . . 056020075
40 . . . . . . . . . . 656033 009
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Motor, 24VDC, 60W, 5300 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, hex M5, Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, rear, gear box assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear, reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, d. 4x35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear, reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear/Shaft, Nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive shaft, central gear/drive roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Snap Ring, 10x16x0,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Snap Ring, 10x16x1,0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing, d. 10x26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, d. 3x13, knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, d.10x14, brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M4x10, zinc steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M4x8, pan head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Pressure Arm Housing, die cast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, upper pressure arm housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, Upper pressure arm pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, insulator drive assembly through bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, drive roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, d. 10,5x4, brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Roll, upper pressure arm housing, d. 17x30 . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, upper drive roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key, upper drive roll assembly, 3x3 L=15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear, upper drive roll assembly, d.17x32.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing, Adapter Gun/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt, M5x50, through housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C clip, gear/shaft, d.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key, lower drive roll assembly, d. 3x3 L=20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear, lower drive roll assembly, d.10x32,5, drive roll . . . . . . . . . . . . . . . . . . . . . . . .
Wire drive Roll, d.30, see fig.7−6 refering to a table 7−1 . . . . . . . . . . . . . . . . . . . . .
O−Ring, d. 7,2x1,78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thumb screw, drive roll locator, d. M4x8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M4x4, wire inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Inlet Guide, see fig.7−6 refering to a table 7−1 . . . . . . . . . . . . . . . . . . . . . . . . .
Tension Arm threaded assembly, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sleeve, d. 6x6, spring housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, wire tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Adjustment tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, locating, tension knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
4
1
1
1
1
1
1
1
1
1
1
1
3
2
1
1
1
4
1
2
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
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 43
Table 7-1. Drive Roll And Wire Guide Kits (2 Roll Models)
NOTE
Base selection of drive rolls upon the following recommended usages:
1. V-Grooved rolls for hard wire.
2. U-Grooved rolls for soft and soft shelled cored wires.
3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4. V-Knurled rolls for hard shelled cored wires.
5. Drive roll types may be mixed to suit particular requirements (example:
V-Knurled roll in combination with U-Grooved).
Wire Diameter
Drive Roll
Wire Guide
Metric
Fraction
Decimal
Part No.
Type
0.6/0.8 mm*
0.023/0.030 in
0.023/0.030 in
156053051
V
0.8/1.0 mm*
0.030/0.035 in
0.030/0.035 in
156053109
V
1.0/1.2 mm*
0.035/0.045 in
0.035/0.045 in
156053052
V
0.8/1.0 mm**
0.035/0.045 in
0.030/0.035 in
156053053
U
1.2/1.6 mm**
0.045/0.065 in
0.035/0.065 in
156053054
U
1.0/1.2 mm*
0.035/0.045 in
0.035/0.045 in
1560531110
V-K
* Available in: steel, 30 mm diameter
**Available in: nylon, 30 mm diameter
OM-246 691 Page 44
Inlet
156090022
Notes
Notes
Effective January 1, 2013
(Equipment with a serial number preface of MD or newer)
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, ITW Welding Products Italy 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 the
equipment was delivered to the original retail purchaser or one
year after the equipment is shipped to a European distributor or
eighteen months after the equipment is shipped to an
International distributor.
1.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Auto-Darkening Helmet Lenses (No Labor)
Migmatic 175
HF Units
Water
Coolant
Systems
(EU
Models,
Non-Integrated)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
5.
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
Inverter Power Sources (Unless Otherwise Stated)
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Transformer/Rectifier Power Sources
Water Coolant System (Integrated)
2 Years — Parts
*
*
*
*
4.
Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules with
exclusion of STR, Si, STi, STH and MPi series.
Automatic Motion Devices
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.)
Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Powered Air Purifying Respirator (PAPR) Blower
Unit (No Labor)
Racks
Running Gear and Trailers
Subarc Wire Drive Assemblies
Water
Coolant
Systems
(USA
Models,
Non-Integrated)
Work Stations/Weld Tables (No Labor)
6 Months — Parts
*
Batteries
90 Days — Parts
*
Accessory (Kits)
*
Canvas Covers
*
Induction Heating Coils and Blankets
*
MIG Guns
*
Remote Controls
*
Replacement Parts (No Labor)
*
Spoolmate Spoolguns
*
Cables and Non-Electronic Controls
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, switches, slip
rings, relays or parts that fail due to normal wear.
2.
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.
3.
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.
5 Years Parts — 3 Years Labor
*
2.
6.
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 ITW Welding Products
Group Europe 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.
milan_warr 2013−01
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
Country
Zip/Postal Code
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Service and Repair
Replacement Parts
Owner’s Manuals
ITW Welding Italy S.r.l.
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
 2013 Miller Electric Mfg. Co. 2013−01
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39 (0) 2982901
Fax: 39 (0) 298290-203
email: miller@itw−welding.it
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