Instruction/ maintenance manual of the product 24A Miller Electric
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Processes Description MIG (GMAW) W elding Flux Cored (FCA W ) W elding Wire Feeder OM-193 472N 2006 − 05 22A, 24A V isit our website at www.MillerWelds.
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 specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-193 472 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown i n the adjoining symbols.
OM-193 472 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
OM-193 472 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.
OM-193 472 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .
OM-193 472 Pa ge 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
OM-193 472 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
OM-193 472 Pa ge 7 2-3 . Dange rs suppléme ntaire s en r e lation avec l’installa tion, le f onc tionneme nt e t l a maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables.
OM-193 472 Page 8 2-5. Princi pales nor mes de sécur ité Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .
OM-193 472 Page 9 SECTION 3 − INST ALLA TION 3-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating Overall Dimensions W eight 24 V olts AC Single Phase 7 Amperes 50/60 Hz Constant V oltage (CV) DC With 14-Pin And Contactor Control 75 to 750 ipm (1.
OM-193 472 Page 10 3-3. Gun Recommendation T able Process Gun GMA W − Hard or Corded Wires M25 Or M40 FCA W − Self-Shielding Wires GA-40GL 1 CV Welding Power Source With 24 V AC Power 2 CV Welding Power Source Without 24 V AC Power 3 1 15 V olts AC /24 V olts AC Power Adapter 4 14-Pin Control Cord 5 Weld Cable (Required) 6 W ork 3-4.
OM-193 472 Page 1 1 3-6. 14-Pin Plug Information Pin* Pin Information A 24 volts ac with respect to pin G. A J K B Contact closure to A completes 24 volts ac contactor control circuit. A J B K I G Circuit common for 24 volts AC circuit. B C L N H C +10 volts dc output to remote control with respect to pin D.
OM-193 472 Page 12 3-8. Optional Meter Circuit Board Settings Ref. 802 357 / Ref. 186 266 T ools Needed: 1/4 in 1 Meter Circuit Board 2 DIP Switch S2 Set DIP switch S2 for type of welding power source, and desired wire feed speed display (see illustration).
OM-193 472 Page 13 3-9. Motor Start/Burnback Control Ref. 802 357 / 192 653 T o change wire feed starting speed proceed as follows: T urn Off unit and welding power source. Remove wrapper . 1 Motor Board PC1 2 Motor Start Control Potentiometer R73 Remove protective white rubber cap before making adjustment.
OM-193 472 Page 14 3-10. Installing Wire Guide And Drive Roll 801 923-C Install and secure inlet wire guide on either assembly , and intermediate wire guide on 4 drive roll assembly only . Install drive rolls and turn drive roll nut one click. During maintenance intervals, remove drive rolls, and clean grooves using a wire brush.
OM-193 472 Page 15 3-1 1. Installing And Threading W elding Wire T ools Needed: 1 Retaining Ring 2 Hub T ension Adjustment Nut If necessary , move hub on support for use of different size wire spool. Remove retaining ring, and install spool so hub pin fits spool hole.
OM-193 472 Page 16 SECTION 4 − OPERA TION 4-1. Front Panel Controls 1 Optional V oltage/Wire Speed Meter 2 Optional V oltage/Wire Speed Switch Use to choose volts or wire feed speed display . 3 Optional Remote V oltage Control Use to set welding power source voltage at the wire feeder .
OM-193 472 Page 17 4-2. Optional Side Panel Controls Ref. 802 357-A / Ref. 186 589 / 210 436-A 1 Preflow Control Control sets time gas flows before welding wire is energized. T ime range is 0 to 5 seconds. 2 Postflow Control Control sets time gas flows after completion of burnback.
OM-193 472 Page 18 5-2. Overload Protection Y T urn Off wire feeder and welding power source. Stop engine on welding generator . 1 Circuit Breaker CB1 CB 1 protects wire feeder from over- load. Correct problem and manually reset breaker . 802 349-A 1 5-3.
OM-193 472 Page 19 SECTION 6 − ELECTRICAL DIAGRAM 210 430-A Figure 6-1. Circuit Diagram For Wire Feeder With Optional Equipment.
OM-193 472 Page 20 SECTION 7 − P ARTS LIST Figure 7.1. Main Assembly 802 358-F . Hardware is common and not available unless listed. 10 Figure 7-2 & Figure 7-3 38 40 39 33 35 36 34 32 31 30 37 4.
OM-193 472 Page 21 Figure 7-1. Main Assembly Diagram marking Item No. Part No. Description Quantity 1 089 899 LA TCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-193 472 Page 22 Diagram marking Item No. Part No. Description Quantity Figure 7-1. Main Assembly (Continued) ♦ 1 15 443 ST AND-OFF , 6-32 x .750 lg 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-193 472 Page 23 Diagram marking Item No. Part No. Description Quantit y Figure 7-2. Drive Assembly , Wire (2 Drive Roll) (Fig 7-1 Item 40) 1 602 009 SCREW , .250-20 x 1.250 soc hd hex gr 8 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-193 472 Page 24 Diagram marking Item No. Part No. Description Quantity Figure 7-3. Drive Assembly , Wire (4 Drive Roll) (Fig 7-1 Item 40) 1 602 009 SCREW , .250-20 x 1.250 soc hd hex gr 8 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-193 472 Page 25 T able 7-1. Drive Roll And Wire Guide Kits (2 Drive Roll) 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).
OM-193 472 Page 26 T able 7-2. Drive Roll & Wire Guide Kits (4 Drive Roll) 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).
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters.
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If you have not bought Miller Electric 24A yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric 24A - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric 24A you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric 24A will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric 24A, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric 24A.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric 24A. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric 24A along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
