Miller Electric Migmatic 271, Owner'S Manual

Page 1: ...matic 271 273 293 333 383 Processes Description MIG GMAW Welding Flux Cored FCAW Welding Arc Welding Power Source Wire Feeder OM 223 194E 2006 09 Effective with serial number 226 213 www MillerWelds com R ...

Page 2: ...ducts 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 par...

Page 3: ...1 3 7 Electrical Service Guide 11 3 8 Selecting a Location and Connecting Input Power 1 Phase and 3 Phase 12 3 9 Installing Drive Rolls and Wire Guide 13 3 10 Aligning Drive Rolls and Wire Guide 13 3 11 Threading Welding Wire and Adjusting Pressure Roll Tension 14 3 12 Using Gun Cable Holder 15 3 13 Setting Gun Polarity for Wire Type Optional 15 SECTION 4 OPERATION 16 4 1 Controls for Migmatic 271...

Page 4: ...98290 1 Fax 39 02 98290203 European Contact Signature Declares that this product Migmatic 271 273 293 333 383 conforms to the following Directives and Standards Directives Electromagnetic Compatibility Directives 89 336 EEC Low Voltage 73 23 EEC Machinery Directives 89 392 EEC And their amendments 91 368 EEC 92 31 EEC 93 44 EEC 93 68 EEC 98 37 EC Standards Electromagnetic compatibility EMC EN50199...

Page 5: ...10 147 see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach prop...

Page 6: ...ombustibles such as a butane lighter or matches from your person before doing any welding 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 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 shield...

Page 7: ...es computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion D If notified by the FCC about interference stop using the equipmentat once D Have the installation regularly checked and maintaine...

Page 8: ...A Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 6 EMF Information Considerations About Welding And The...

Page 9: ...parks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with corr...

Page 10: ...e 4 Having a loop of extra length connect grounding conductor first 5 Connect line input conductors as shown on inside label double check all connections jumper link positions and input voltage before applying power 1 Warning Watch Out There are possible hazards as shown by the symbols 2 Moving parts such as fans can cut fingers and hands and cause injury Keep away from moving parts S 176 106 1 2 ...

Page 11: ... glasses 5 Electrode Positive Straight Polarity Place terminal strips as shown 6 Electrode Negative reverse Polarity Place terminal strips as shown 5 6 1 2 3 4 Do not discard this product with general waste Reuse or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collec tion facility Contact your local recycling office or your local distributor for further infor...

Page 12: ...put Max Open Ci i Rated Input Amperage at Rated Output Di i W i ht Model 100 50 35 Open Circuit Voltage 230 V 400 V Dimension mm Weight kg 293 210 A 24 V 230 A 25 V 270 A 27 5 V 49 30 A 3 A 18 A 1 38 A 480 x 800 x 1050 90 108 Net Wire feed speed range 1 3 mpm to 20 mpm While idling Max Rated Input Amperage Rated Output Max Open Ci i Rated Input Amperage at Rated Output Di i W i ht Model 100 50 35 ...

Page 13: ...efore welding Y Exceeding duty cycle can damage unit and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes 60 Duty Cycle At 400 Amperes 100 Duty Cycle At 300 Amperes sduty1 5 95 187 478 A DUTY CYCLE Continuous Welding 3 3 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 othe...

Page 14: ...fall and break off valve 1 Regulator FlowGauge Install so face is vertical 2 Gas Hose Connection 3 Flow Adjust Typical flow rate is 0 9 liters per minute Check wire manufactur er s recommended flow rate This flow gauge can be adjusted be tween 2 36 and 11 8 liters per min ute 3 5 Installing Wire Spool and Adjusting Hub Tension Nov 16 2005 When a slight force is needed to turn spool tension is set ...

Page 15: ... Rated Output 35 23 13 30 18 32 19 38 22 Max Recommended Standard Fuse or Circuit Breaker Rating in Am peres 35 23 13 30 18 32 19 38 22 Input Conductor Size in mm2 4 2 5 2 5 6 4 6 4 6 4 Grounding Conductor Size in mm2 4 2 5 2 5 6 4 6 4 6 4 Power cord supplied with the unit is sized for 230V operation Larger power cord may be required for cable lengths greater than 3 meters Consult national and loc...

Page 16: ...nput Power 1 Phase and 3 Phase Have only qualified persons make this installation 1 Rating Label Supply correct input power 18 in 457 mm for airflow 1 Phase Primary Connection 3 Phase Primary Connection GND PE Connect First GND PE Connect First 1 L1 L2 L1 L2 L3 ...

Page 17: ...site side of the drive roll The groove closest to the motor shaft is the proper groove to thread 5 Drive Roll Securing Nut Turn nut one click to secure drive roll Tools Needed 5 64 in 7 16 in 1 3 2 4 5 3 10 Aligning Drive Rolls and Wire Guide Y Turn Off power View is from top of drive rolls looking down with pressure assembly open 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire ...

Page 18: ...e assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn On Press gun trigger until wire comes out of gun Reinstall contact tip and nozzle Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close and latch door Ref 802 064 D S ...

Page 19: ... 12 Using Gun Cable Holder 3 4 3 13 Setting Gun Polarity for Wire Type Optional 1 Terminal Cover Protects Polarity Change over ter minals from accidental contact Re move cover to gain access 2 Electrode Positive DCEP For solid steel stainless steel alu minum or flux core with gas wires GMAW 3 Electrode Negative DCEN For gasless flux core wires FCAW wire drive assembly be comes negative 1 2 3 ...

Page 20: ...s are lo cated under the hinged side wire consumable access door Optional 4 2 Controls for Migmatic 293 333 1 2 3 4 6 7 8 9 5 1 Voltage Control Fine Adjust Turn control clockwise to increase voltage 2 Voltage Control Coarse Adjust Turn control clockwise to increase voltage 3 2T 4T Trigger Hold Function Latching Torch Trigger 4 Power Switch 5 Work Lead Connection 6 MIG Torch Connection 7 Digital Di...

Page 21: ...eed speed 10 Digital Display Volts Amps Wire Feed Speed with last value hold function Trigger mode 2T 4T is shown at power on for 3 seconds and when Trigger mode is changed Not shown Jog and Purge controls are lo cated under the hinged side wire consumable access door Optional 6 4 4 Run In Burnback Optional and Spot Weld Timer Controls 1 Run In Control Speed of wire prior to striking a welding arc...

Page 22: ...aker CB1 1 Circuit Breaker CB1 CB1 protects the unit from over loading of drive motor M1 If CB1 opens wire feeding stops 2 Welding Gun Check gun liner for blockage or kinks 3 Wire Drive Assembly Check for jammed wire binding drive gear or misaligned drive rolls Allow cooling period and reset breaker Close door 3 1 2 5 3 Unit Overload Thermal switches TP1 in XFMR and TP2 in SR1 protect the unit fro...

Page 23: ...and check connections Replace Z1 if necessary Check main transformer T1 for signs of winding failure Check continuity across windings and check con nections Check secondary voltages Replace T1 if necessary 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 6 Check input voltage jumper links and correct positi...

Page 24: ...OM 223 194 Page 20 Notes ...

Page 25: ...WARNING Electric Shock Hazard S Do not touch live electrical parts S Disconnect input power or stop engine before servicing S Do not operate with covers removed S Have only qualified persons install use or service this unit Figure 6 1 Circuit Diagram for Migmatic 271 ...

Page 26: ...ock Hazard S Do not touch live electrical parts S Disconnect input power or stop engine before servicing S Do not operate with covers removed S Have only qualified persons install use or service this unit Figure 6 2 Circuit Diagram for Migmatic 273 400 VAC ...

Page 27: ...ock Hazard S Do not touch live electrical parts S Disconnect input power or stop engine before servicing S Do not operate with covers removed S Have only qualified persons install use or service this unit Figure 6 3 Circuit Diagram for Migmatic 293 400 VAC ...

Page 28: ...ock Hazard S Do not touch live electrical parts S Disconnect input power or stop engine before servicing S Do not operate with covers removed S Have only qualified persons install use or service this unit Figure 6 4 Circuit Diagram for Migmatic 333 400 VAC ...

Page 29: ...ock Hazard S Do not touch live electrical parts S Disconnect input power or stop engine before servicing S Do not operate with covers removed S Have only qualified persons install use or service this unit Figure 6 5 Circuit Diagram for Migmatic 383 400 VAC ...

Page 30: ...OM 223 194 Page 26 SECTION 7 PARTS LIST Figure 7 1 Wrapper Assembly All Models ...

Page 31: ...el 1 12 156121023 Wrapper R H side fixed 271 273 293 1 12 156121027 Wrapper R H side fixed 333 383 1 13 000197555 Gun and cable Holder assy 1 14 000207233 Label general precautionary 1 15 056054068 Wheel Caster front 80 O D 2 16 316029701 Nameplate lower Migmatic 271 1 16 316029702 Nameplate lower Migmatic 273 1 16 316029706 Nameplate lower Migmatic 293 1 16 316029703 Nameplate lower Migmatic 333 ...

Page 32: ...OM 223 194 Page 28 April 17 2006 Figure 7 2 Main Assembly for Migmatic 271 ...

Page 33: ...it Breaker 1 25 156006038 Base 1 26 Z1 058028016 Stabilizer 1 27 C1 056082091 Capacitor 1600 80μp VDC 4 28 058021141 Transformer auxiliary 1 29 057079033 W Contactor 11Kw 230VAC 50 60Hz 1 30 056126073 Fan motor assembly consisting of 1 FM1 056126073 Fan motor 230 VAC 1 356078037 Blade 250Ø 27_ 1 31 000176106 Label safety caution moving parts 1 32 116117074 Cowling fan assembly 1 33 000006393 Relay...

Page 34: ...OM 223 194 Page 30 April 17 2006 Figure 7 3 Main Assembly for Migmatic 273 ...

Page 35: ...006038 Base 1 26 556070011 Link primary power terminal 230 400 models 4 27 756069012 Primary power terminal board 230 400 models 1 28 058021141 Transformer auxiliary 1 29 W 057079032 Contactor 7 5 Kw 230VAC 50 60Hz 1 30 Fan motor assembly consisting of 1 FM1 056126073 Fan motor 230 VAC 1 356078037 Blade 250 Ø 27_ 1 31 000176106 Label safety caution moving parts 1 32 116117074 Cowling fan assembly ...

Page 36: ...OM 223 194 Page 32 April 17 2006 Figure 7 4 Main Assembly for Migmatic 293 ...

Page 37: ...ower terminal 4 27 756069012 Primary power terminal board 230 400 models 1 28 058021141 Transformer auxiliary 1 1 29 W 057079032 Contactor 7 5 Kw 230VAC 50 60Hz 1 29 W 057070033 Contactor 11 Kw 230VAC 50 60Hz 1 30 Fan motor assembly consisting of 1 1 FM1 056126073 Fan motor 230 VAC 1 1 356078037 Blade 250 Ø 27_ 1 1 31 000176106 Label safety caution moving parts 1 1 32 116117074 Cowling fan assembl...

Page 38: ...OM 223 194 Page 34 April 17 2006 Figure 7 5 Main Assembly for Migmatic 333 ...

Page 39: ...27 028021457 Transformer main 230 400 VAC 50 Hz c w 1 TP1 056159025 Thermal Switch PTC 130_ C 1 1 28 556070011 Link primary power terminal 4 29 756069012 Primary power terminal board 230 400 models 1 30 Z1 058028012 Stabilizer 1 1 31 Fan motor assembly consisting of FM1 056126073 Fan motor 230 VAC 1 1 356078037 Blade 250 Ø 27_ 1 1 32 W 057079032 Contactor 7 5 Kw 230 VAC 50 60 Hz 1 32 W 057070033 C...

Page 40: ...OM 223 194 Page 36 April 17 2006 Figure 7 6 Main Assembly for Migmatic 383 ...

Page 41: ...ormer main 230 400 VAC 50 Hz c w 1 TP1 056159025 Thermal Switch PTC 130_ C 1 1 28 556070011 Link primary power terminal 4 29 756069012 Primary power terminal board 230 400 models 1 30 Z1 058028017 Stabilizer 1 1 31 Fan motor assembly consisting of FM1 056126073 Fan motor 230 VAC 1 1 356078037 Blade 250 Ø 27_ 1 1 32 W 057079032 Contactor 7 5 Kw 230 VAC 50 60 Hz 1 32 W 057079033 Contactor 11 Kw 230 ...

Page 42: ...73 619 Carrier drive roll w components 1 9 602 239 Washer central Drive gear shaft drive carrier 1 10 174 609 Screw central drive gear shaft 1 11 602 009 Screw soc head hex 1 12 172 075 Carrier drive roll w components 1 13 601 872 Nut power stud terminal 1 14 602 213 Washer spring 1 15 010 224 Pin spring CS 187 x 1 000 1 16 085 242 Fastener pinned 1 17 196 896 Cup spring 1 18 196 897 Spring cprsn ...

Page 43: ...adapter housing 2 12 173 618 Drive Gear central 2 13 602 239 Washer central drive gear shaft 1 14 174 609 Screw central drive gear shaft 1 15 602 009 Screw soc head hex 4 16 172 075 Carrier drive roll w component 24 pitch 4 17 601 872 Nut power stud 1 18 602 213 Washer plain power stud 1 19 010 224 Pin tension arm 2 20 166 071 Lever mtg pressure gear 1 21 089 562 Tension arm pinned 2 22 085 244 Wa...

Page 44: ...49 072 000 U Grooved 056 192 1 2 mm 0 045 in 0 045 in 079 599 053 701 U Grooved 056 193 1 0 mm 0 035 in 0 035 in 079 606 132 958 V Knurled 056 192 1 2 mm 0 045 in 0 045 in 079 607 132 957 V Knurled 056 193 1 2 mm 0 045 in 0 045 in 083 318 083 489 U Cogged 056 193 Table 7 2 Drive Roll And Wire Guide Kits 4 Roll Models Wire Diameter Kit No Drive Roll Wire Guide Metric Fraction Decimal Kit No Part No...

Page 45: ...Notes ...

Page 46: ...Notes ...

Page 47: ... shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes 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 be...

Page 48: ...ostal Code Please complete and retain with your personal records Owner s Record Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Service and Repair Replacement Parts Owner s Manuals Contact the Delivering Carrier to For Service File a claim for loss or damage during shipment For assistance in...