OM-188 414C
January 2000
Effective with serial number : 165 748
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source and
Wire Feeder
INTEGRA 201/241
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TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Installing Drive Roll and Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Installing Wire Spool and Adjusting Hub Tension . . . . . . . . . . . . . . . . . . .
2-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Selecting a Location and Connecting Input Power . . . . . . . . . . . . . . . . . .
2-9. Installing Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
5
5
5
6
6
7
7
7
8
8
9
9
SECTION 4 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . 10
4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-3. Unit Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 5 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 6 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WARRANTY
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Declaration of Conformity
Manufactruer’s Name:
MILLER Europe S.P.A.
Manufacturer’s Address:
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Declares that this product:
INTEGRA 201/241
Conforms to the following Directives and Standards:
Directives
Electromagnetic Compatibility Directives: 89/336/EEC
Low Voltage: 73/23/EEC
Machinery Directives: 89/392/EEC
And their amendments 91/368/EEC, 93/31/EEC, 93/44/EEC, 93/68/EEC
Standards
Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995
Safety Requirements for Arc Welding Equipment Part 1: EN 60974-1: 1989
European Contact:
Mr. Luigi Vacchini, Managing Director
MILLER Europe S.P.A.
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Telephone:
Fax:
39(0)2-982901
39(0)2-98290-203
dec_con 5/97
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
Y
Marks a special safety message.
. Means “Note”; not safety related.
1-2. Arc Welding Hazards
Y
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
D
D
D
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D
D
D
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Y
Y
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D
D
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
ELECTRIC SHOCK can kill.
Do not connect more than one electrode or work cable to any
single weld output terminal.
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
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
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
groundedequipment is a hazard.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D
D
D
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
FUMES AND GASES can be hazardous.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
D
D
Use AC output ONLY if required for the welding process.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If AC output is required, use remote output control if present on
unit.
D
D
If ventilation is poor, use an approved air-supplied respirator.
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).
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D
D
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
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
groundedreceptacle outlet.
D
D
Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D
D
When making input connections, attach proper grounding conduc-
tor first – double-check connections.
Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-suppliedrespirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
D
D
D
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
OM-188 414 Page 1
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ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
D
D
Shut off shielding gas supply when not in use.
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.
Always ventilate confined spaces or use
approved air-supplied respirator.
D
Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
HOT PARTS can cause severe burns.
D
D
D
Wear approved safety glasses with side shields under your
helmet.
D
D
Do not touch hot parts bare handed.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Allow cooling period before working on gun or
torch.
Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
D
D
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
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.
NOISE can damage hearing.
D
D
D
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Noise from some processes or equipment can
damagehearing.
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
Wear approved ear protection if noise level is
high.
D
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D
D
Watch for fire, and keep a fire extinguisher nearby.
CYLINDERS can explode if damaged.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D
D
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D
D
Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D
D
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D
D
D
D
D
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
D
D
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
FLYING METAL can injure eyes.
D
D
Turn face away from valve outlet when opening cylinder valve.
D
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
D
Wear approved safety glasses with side
shields even under your welding helmet.
OM-188 414 Page 2
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D
Do not install or place unit on, over, or near
combustiblesurfaces.
D
D
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
D
Do not install unit near flammables.
D
Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D
D
D
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Use equipment of adequate capacity to lift and
support unit.
D
Have only qualified persons familiar with
electronic equipment perform this installation.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
D
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
If notified by the FCC about interference, stop using the
equipmentat once.
OVERUSE can cause OVERHEATING
D
D
Allow cooling period; follow rated duty cycle.
D
D
Have the installation regularly checked and maintained.
Reduce current or reduce duty cycle before
starting to weld again.
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
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
D
D
Put on grounded wrist strap BEFORE handling
boards or parts.
ARC WELDING can cause interference.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
MOVING PARTS can cause injury.
D
Be sure all equipment in the welding area is
electromagneticallycompatible.
D
D
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
D
D
D
D
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 elec-
tronic equipment.
WELDING WIRE can cause injury.
Be sure this welding machine is installed and grounded
according to this manual.
D
D
Do not press gun trigger until instructed to do
so.
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.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-188 414 Page 3
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1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
To reduce magnetic fields in the workplace, use the following
procedures:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-188 414 Page 4
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SECTION 2 – INSTALLATION
2-1. Specifications
Rated Input
Amperage at Rated
Output
Rated Output
Max. Open
100%
60%
20%
230 V
Circuit Voltage
Model
Dimension (mm)
Weight (kg)
90 A
18.5 V
116 A
20 V
200 A
24 V
26A
2A*
201
38
41
310 x 540 x 957
70
115 A
20 V
150 A
21 V
240 A
26 V
35A
2.5A*
241
310 x 540 x 957
80
Wire feed speed range 1.8 mpm to 18 mpm.
* While idling
2-2. Duty Cycle and Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
300
250
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.
200
150
Y
Exceeding duty cycle can
damage unit and void
warranty.
241
100
90
201
70 80 90 100
80
20
30
40
50
60
% DUTY CYCLE
60% Duty Cycle at 200 Amperes
40% Duty Cycle at 250 Amperes
6 Minutes Welding
4 Minutes Resting
4 Minutes Welding
6 Minutes Resting
Overheating
A or V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 – SB-150 215
OM-188 414 Page 5
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2-3. Volt-Ampere Curves
1
Normal Volt-Ampere Curves
The volt-ampere curves show the
normal minimum and maximum
voltage and amperage output capa-
bilities of the welding power source.
Curves of other settings fall be-
tween the curves shown.
Model 201
Model 241
dwg. 802004, 802003
2-4. Installing Gas Supply
Chain gas cylinder to running gear,
wall, or other stationary support so
cylinder cannot fall and break off
valve.
1
Regulator/FlowGauge
Install so face is vertical.
2
3
Gas Hose Connection
Flow Adjust
Typical flow rate is 20 cfh (cubic
feet per hour). Check wire man-
ufacturer’s recommended flow
rate. This flow gauge can be
adjusted between 5 and 25 cfh.
1
Argon Gas
OR
2
3
CO Gas
2
Ref. ST-148 265-B / Ref. ST-149 827-B / Ref. ST-158 697-A
OM-188 414 Page 6
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2-5. Installing Drive Roll and Wire Inlet Guide
1
2
Securing Screw
Inlet Wire Guide
3
Loosen screw. Slide tip as close to
drive rolls as possible without touch-
ing. Tighten screw.
5
3
4
Wire Tension Wheel
Drive Roll
Install correct drive roll for wire size
and type.
2
5
Drive Roll Tension Assembly
Turn nut one click to secure drive
roll.
4
1
ST-150 227-C
2-6. Installing Wire Spool and Adjusting Hub Tension
When a slight force is needed to turn spool, tension is set.
Tools Needed:
15/16 in
ST-072573-B
2-7. Electrical Service Guide
201
230
26
26
4
241
230
35
35
4
Input Voltage
Input Amperes at Rated Output
Max Recommended Standard Fuse or Circuit Breaker Rating in Amperes
2
** Input Conductor Size in mm
2
4
4
** Grounding Conductor Size in mm
** Power cord supplied with the unit is sized for 230V operation. Larger power cord may be required for cable lengths greater than 3 meters. C
onsult national and local regulations.
OM-188 414 Page 7
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2-8. Selecting a Location and Connecting Input Power
Have only qualified persons make
this installation.
1
Rating Label
Supply correct input power.
18 in (457 mm)
for airflow
GND/PE
GND/PE
Connect First
L2
L1
1
ST-801 721
2-9. Installing Work Clamp
1
2
3
Wire Feeder Connection
Work Connect
2
3
Negative Power Source
Terminal
4
Positive Power Source
Terminal
4
1
OM-188 414 Page 8
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SECTION 3 – OPERATION
3-1. Controls
1
2
3
4
5
Handle
Wire Speed Control
Pilot Light
Spot Timer
Optional Amperage and Volt-
meter
1
6
7
8
9
Power Switch
Thermal Overload Pilot Light
10 Position Voltage Control
Torch Connector
2
3
4
5
6
9
7
8
OM-188 414 Page 9
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SECTION 4 – MAINTENANCE AND TROUBLESHOOTING
4-1. Routine Maintenance
Y
Disconnectpower before maintaining.
3 Months
Repair or replace
cracked weld cable.
Replace unreadable labels.
Clean and tighten weld terminals.
6 Months
Blow out or vacuum inside. during
heavy service clean monthly.
OR
4-2. Circuit Breaker CB1
1
Circuit Breaker CB1
If CB1 opens, wire feeding stops.
Drive Roll Assembly
2
1
2
4-3. Unit Overload
If unit is used beyond capacity (excessive wire feed, shorted output, etc.), wire feeds but is not energized. Release gun
trigger to reset this condition.
OM-188 414 Page 10
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4-4. Troubleshooting
Trouble
Remedy
No weld output; wire does not feed.
Be sure line disconnect switch is On (see Section 2-8).
Replace building line fuse or reset circuit breaker if open (see Section 2-8).
Reset circuit breaker CB1 (see Section 4-2).
Secure gun trigger connections.
Check and replace Power switch if necessary.
No weld output; overload light on
ThermostatTP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled
(see Section 2-2).
An overload condition occurred. Release gun trigger (see Section 4-3).
Connect unit to proper input voltage or check for low line voltage (see Section 2-8).
Reset circuit breaker CB1 (see Section 4-2).
Low weld output.
No wire feed.
Turn Wire Speed control to higher setting (see Section 3-1).
Clear obstruction in gun contact tip or liner.
Readjust drive roll pressure.
Change to correct size drive rolls (see Section 2-5).
Check gun trigger and leads. Repair or replace gun if necessary.
Have Factory Authorized Service Agent check main control board.
Check polarity setting for type of welding wire being used.
Poor weld bead, or welding
wire is noodle welding.
OM-188 414 Page 11
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SECTION 5 – ELECTRICAL DIAGRAM
5.1 INTEGRA 201
cod.956.142.275
L
N
BLACK
NERO
10
0
ROSSO
RED
5.2 INTEGRA 241
cod.956.142.211
L
N
10
0
OM-188 414 Page 12
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SECTION 6 – PARTS LIST
6.1 Common Parts Assembly
18
9
8
1
2
7
6
4
11
10
3
17
13
6
16
4
12
14
15
Dia
Ref.
Dia
Ref.
Item
Code
Dwg
Qty.
Item
Code
Dwg
Qty.
1
2
3
4
6
7
8
9
10
000151187 PV.0.0.18
116122284 UV.0.0.14
156087017
1
1
2
2
2
1
1
2
1
11
12
13
14
15
16
17
18
156012109 UV.0.0.21
116121100 UV.0.0.15
156034001 BP.2.0.19
057014063 UV.0.7
056054055 QF.5.0.2
156002018 QF.0.0.13
116122285 UV.0.0.16
116123001 DU.0.0.6
1
1
2
1
2
1
1
1
156009067
056054064 VS.0.0.13
116005165 DZ.0.0.25
150005001
156011002
116005316 UV.0.0.17
OM-188 414 Page 13
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6.2 Main Assembly
20
22
18
19
21
24
23
12
25
14
15
22
23
11
13
10
9
28
29
17
16
30
31
8
32
34
26
7
6
27
33
5
47
35
4
49
46
37
48
2
3
1
38
36
45
44
43
40
39
41
42
Dia
Ref.
Qty.
201 241
Dia
Ref.
Qty.
201 241
Item
Code
Dwg
Item
Code
Dwg
1
2
3
4
4
4
4
4
4
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
056052033 MD.4.0.1
156019694 FZ.0.9.1
156019672 MD.4.0.6
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
1
25
26
27
28
29
30
31
32
32
33
34
35
36
37
38
38
39
39
40
40
41
41
116009041 CV.0.0.2
056067188 UV.0.0.9
028061049 QF.6
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
CB
PC
OPTIONAL 156053040 DIA 0.6 V
OPTIONAL 156053036 DIA 0.8 V
OPTIONAL 156053037 DIA 1.0 V
OPTIONAL 156053038 DIA 1.2 V
OPTIONAL 156053041 DIA 1.2 K
OPTIONAL 156053042 DIA 1.0 U
OPTIONAL 156053043 DIA 1.2 U
156076072 MD.4.0.5
056076152 DD.0.0.7
057014065 UT.0.21
027061016 QF.0.21
057014063 UV.0.7
057079026 QF.0.20
057079027 UV.0.12
056091041 QF.0.0.12
058021081 QF.7
056126062 UR.0.0.7
056082091 VU.0.0.4
056061042 UV.0.0.7
056067189 UT.0.0.15
056067201 VU.0.0.2
057093014 UT.0.16
057093017 VU.0.5
028021430 UT.7
W
W
1
1
1
2
4
1
1
1
2
4
1
1
T2
FM
556090033 MD.5.0.1
156076073 MD.4.2.7
656064001 MD.4.2.5
156009112 MD.4.2.4
156032112 MD.4.2.3
056018001 MD.4.2.2
156019671 MD.4.2.1
156017053 MD.4.3.1
GS
S2
S2
SR1
SR1
MT
MT
Z1
1
1
1
1
1
1
156017054 MD.4.3.2
028021428 VU.4
028038042 UT.8
057110002 VU.1
M
F1
057010048 QF.0.23
056092039 FZ.4.0.5
000046432 OL.0.0.14
156018033
Z1
1
1
1
1
1
1
2
1
42 OPTIONAL 057095010 VS.0.19
1
1
1
1
1
2
1
1
43
44
45
46
47
48
49
056020029 MM.3.0.2
056067157 MQ.0.0.1
056072062 QF.0.0.10
756005012 FU.1.6.1
000097922 BP.2.0.20
057052019 QF.0.13
057094033 UQ.0.3
156009079
S1
156022064 GF.1.0.4
156009075 GF.1.0.2
000010191 FU.1.0.6
000058628 FU.1.0.7
656102001 BH.0.0.3
OM-188 414 Page 14
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Effective January 1, 2000
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin,
warrants to its original retail purchaser that new Miller
equipment sold after the effective date of this limited warranty
is free of defects in material and workmanship at the time it is
shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
*
*
*
*
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate 185 and Spoolmate 250
IMPLIED, INCLUDING
THE
WARRANTIES OF
MERCHANTABILITY AND FITNESS.
Miller’s True Blue Limited Warranty shall not apply to:
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.
1. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
2. Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser,
or one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to
an International distributor.
3. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
1. 5 Years Parts – 3 Years Labor
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.
*
*
Original main power rectifiers
Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
*
*
*
*
*
*
Transformer/Rectifier Power Sources
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the
goods at customer’s risk and expense. Miller’s option of
repair or replacement will be F.O.B., Factory at Appleton,
Wisconsin, or F.O.B. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
3. 1 Year — Parts and Labor
*
*
DS-2 Feeder
Motor Driven Guns (w/exception of Spoolmate 185
and Spoolmate 250)
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.
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
IHPS Power Sources
Water Coolant Systems
HF Units
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.
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT
Models)
&
SAF
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
*
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.)
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated
herein, and to the extent that they may not be waived, the
limitations and exclusions set out above may not apply. This
Limited Warranty provides specific legal rights, and other
rights may be available, but may vary from province to
province.
4. 6 Months — Batteries
5. 90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction heating coils and blankets
milan_warr 4/00
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Serial/Style Number
(Date which equipment was delivered to original customer.)
Address
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
Phone: 414-735-4505
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Miller Europe
Italy
Phone: 39 (0) 2982901
PRINTED IN USA
2000 Miller Electric Mfg. Co. 1/00
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