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Miller Electric Millermatic 250, Owner'S Manual

The Miller Electric Millermatic 250 is a powerful and reliable welding machine designed for professional welders. For complete instructions on how to operate this machine, make sure to download the free Owner's Manual from manualshive.com. This comprehensive manual will provide you with all the information you need to get started with your welding projects.

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OM-1308 Page 19

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 6-1. Main Assembly

Quantity

1

148 597

COUPLER, rod threaded .312-18 x 1.000

1

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

2

146 168

PANEL, center enclosure

1

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

3

PLG7

083 526

HOUSING RECEPTACLE & SOCKETS

1

. . . 

. . 

. . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

4

Fig 6-2

BAFFLE, center w/components

1

. . . 

. . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5

T1

174 553

TRANSFORMER, pwr main (200/230/460) (consisting of)

1

. . . 

. . . . 

. . . 

. . . 

. . . . . . . . . . . . . . . 

5

T1

174 554

TRANSFORMER, pwr main (230/460/575) (consisting of)

1

. . . 

. . . . 

. . . 

. . . 

. . . . . . . . . . . . . . . 

5

T1

174 552

TRANSFORMER, pwr main (220/380/415) (consisting of)

1

. . . 

. . . . 

. . . 

. . . 

. . . . . . . . . . . . . . . 

TP3

121 497

THERMOSTAT

1

. . . . . . . . . 

. . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

6

150 387

BAFFLE, air transformer

1

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

7

602 250

WASHER, flat stl SAE .750

2

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

8

186 758

WHEEL

2

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

9

Z1

143 892

STABILIZER, (60Hz)

1

. . . 

. . . . 

. . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

9

Z1

150 385

STABILIZER, (50Hz)

1

. . . 

. . . . 

. . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

10

Fig 6-5

PANEL, rear w/components

1

. . . 

. . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

11

146 165

PANEL, side LH

1

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

12

089 899

LATCH, slide flush mtg hole 1.000 wide x 1.500 lg

2

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . 

13

+146 167

PANEL, side

1

. . . 

. . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

146 991

LABEL, weld parameters

1

. . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14

134 464

LABEL, warning general precautionary

1

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15

+170 513

WRAPPER 

1

. . . 

. . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

117 860

BLANK, snap-in nyl .187mtg hole

2

. . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

16

PLG20

144 086

CORD SET, pwr 250V 8-10ga 3/c 600V 12ft (200/230V)

1

. . . 

. . 

. 

. . . 

. . . . . . . . . . . . . . . . . 

039 778

RECEPTACLE, str 2P3W 50A 250V (200/230V only)

1

. . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . 

16

144 085

CORD SET, pwr 8-10ga 3/c 600V 12ft

1

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17

146 161

BASE

1

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18

052 692

AXLE, running gear (consisting of)

1

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19

121 614

RING, retaining ext .750 shaft x .085grv depth

2

. . . 

. . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . 

20

SR1

173 713

RECTIFIER, SCR main (consisting of)

1

. . . 

. . . 

. . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

166 667

CLAMP, spring thyristor rectifier

1

. . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

173 784

HEAT SINK, rectifier

2

. . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

C3,4

031 689

CAPACITOR, rectifier

2

. . . . . . . . . 

. . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

143 818

THYRISTOR, SCR 325A 300V hockey puck

2

. . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . 

TP1

154 243

THERMOSTAT, NC

1

. . . . . . . . . 

. . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

171 405

HEAT SINK, rectifier

1

. . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

143 852

FOOT, mtg rectifier

2

. . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

TP2

154 244

THERMOSTAT, NO

1

. . . . . . . . . 

. . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

173 714

CLAMP, thyristor rectifier

1

. . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21

602 213

WASHER, lock stl split .375

2

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

22

008 999

CASTER, plstc swvl 4 in dia

2

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

23

601 871

NUT, stl hex jam .375-16

2

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

24

Fig 6-3

PANEL, front w/components

1

. . . 

. . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

25

169 596

GUN, 12ft .030-.035 wire (Fig 6-6)

1

. . . 

. . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

182 137

REGULATOR/FLOWMETER, 10-50 CFH Argon/CO

2

1

. . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . 

144 108

HOSE, gas

1

. . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

130 750

CLAMP, ground 350A

1

. . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

600 318

CABLE, weld cop strd No. 3 (order by ft)

10ft

. . . . . . . . . . . . . . . . . 

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

+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.

Summary of Contents for Millermatic 250

Page 1: ...ocesses Description Gas Metal Arc MIG Welding Flux Cored Arc FCAW Welding Arc Welding Power Source And Wire Feeder OM 1308 144 212N March 1998 Millermatic 250 R Visit our website at www MillerWelds co...

Page 2: ...alue 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 agains...

Page 3: ...Wire Spool And Adjusting Hub Tension 8 2 9 Positioning Jumper Links 8 2 10 Electrical Service Guide 9 2 11 Selecting A Location And Connecting Input Power 9 2 12 Threading Welding Wire 10 SECTION 3 OP...

Page 4: ......

Page 5: ...connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power cord for damage or...

Page 6: ...lding 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 light...

Page 7: ...aintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can caus...

Page 8: ...s 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 el...

Page 9: ...1 2 mm 023 035 in 0 6 0 9 mm 030 045 in 0 8 1 2 mm 1 2 1 7 m min W 19 in 483 mm D 30 1 4 in 768 mm 102 kg While idling 2 2 Duty Cycle And Overheating 4 Minutes Welding 6 Minutes Resting 6 Minutes Weld...

Page 10: ...d lower weld voltage set ting before trying to weld This shut down circuitry protects internal circuits and parts from overload damage 0 10 20 30 40 50 60 0 50 100 150 200 250 300 350 400 DC VOLTS DC...

Page 11: ...r wall or other station ary support so cylinder cannot fall and break off valve 1 Cap 2 Cylinder Valve Remove cap stand to side of valve and open valve slightly Gas flow blows dust and dirt from valve...

Page 12: ...tioning Jumper Links 220 VOLTS 380 VOLTS 415 VOLTS S 144 915 A Ref ST 148 263 C Check input voltage available at site 1 Jumper Links Access Door Open door 2 Jumper Link Label Check label only one is o...

Page 13: ...rounding Conductor Size In AWG Kcmil 8 10 10 12 12 10 12 Reference 1996 National Electrical Code NEC S 0092J 2 11 Selecting A Location And Connecting Input Power Have only qualified persons make this...

Page 14: ...in 150 mm Hold wire tightly to keep it from unraveling 4 in 102 mm Tighten WOOD Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and ti...

Page 15: ...Range when wire speed is between 50 and 350 ipm 4 Pilot Light 5 Power Switch 1 2 3 5 4 3 2 Installing Receptacle Module For Use With A Spool Gun Optional ST 801 732 Remove existing options panel 1 Mo...

Page 16: ...carrier Apply light coat of oil or grease to drive motor shaft 4 2 Circuit Breaker CB1 Ref ST 148 261 C 1 Circuit Breaker CB1 If CB1 opens wire feeding stops 2 Welding Gun Check gun liner for blockage...

Page 17: ...all guide as shown 4 Drive Roll Install correct drive roll for wire size and type 5 Drive Roll Securing Nut Turn nut one click to secure drive roll 5 64 in 7 16 in 4 6 Aligning Drive Rolls And Wire Gu...

Page 18: ...tighten wire outlet guide Cut liner off 3 4 in 20 mm 3 8 in 9 5 mm for aluminum from head tube Install adapter contact tip and nozzle Lay gun cable out straight before installing new liner Head tube 3...

Page 19: ...th handle locking nut If replacing head tube continue to end of figure 3 Slide handle 4 Secure head tube in vice 5 Remove shock wash ers from front and rear of head tube 6 Loosen jam nut Remove from v...

Page 20: ...e Factory Authorized Service Agent check main control board Fan motor does not run NOTE Fan only runs when cooling is necessary Have Factory Authorized Service Agent check fan on demand circuit Low hi...

Page 21: ...OM 1308 Page 17 SECTION 5 ELECTRICAL DIAGRAM SC 175 883 A Figure 5 1 Circuit Diagram...

Page 22: ...18 SECTION 6 PARTS LIST ST 801 717 1 2 3 4 Fig 6 2 5 6 7 8 9 10 Fig 6 5 11 12 13 14 15 16 17 19 7 8 20 21 22 23 Fig 6 3 24 18 Fig 6 6 25 Hardware is common and not available unless listed Figure 6 1 M...

Page 23: ...r 2P3W 50A 250V 200 230V only 1 16 144 085 CORD SET pwr 8 10ga 3 c 600V 12ft 1 17 146 161 BASE 1 18 052 692 AXLE running gear consisting of 1 19 121 614 RING retaining ext 750 shaft x 085grv depth 2 2...

Page 24: ...age 20 10 11 12 13 14 15 17 18 19 20 21 16 22 23 24 25 26 27 29 30 34 Fig 6 4 33 32 31 ST 148 325 D 9 28 Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 Figure 6 2 Baffle Center w C...

Page 25: ...x 031thk 6 18 038 887 STUD pri bd brs 10 32 x 1 375 6 19 083 426 TERMINAL BOARD pri 1 20 601 835 NUT brs hex 10 32 12 21 038 618 LINK jumper term bd pri 2 22 010 199 TUBING stl 275 ID x 048 wall x 1...

Page 26: ...9 C10 175 719 LEAD ASSEMBLY elect 1 10 RC1 048 282 RECEPTACLE w SOCKETS 1 11 S1 128 755 SWITCH tgl DPST 40A 600VAC 1 12 174 814 PANEL front 1 13 PLATE indicator lower order by model and serial number...

Page 27: ...r 24VDC 122RPM 20 1 ratio 1 15 079 633 FITTING hose brs barbed M 3 16tbg 1 16 601 966 SCREW 375 16 x 1 25hexhd 3 17 145 237 STOP cover 1 18 604 538 WASHER flat stl SAE 312 1 19 124 778 KNOB plstc T 1...

Page 28: ...cription Part No Dia Mkgs Item No Figure 6 5 Panel Rear w Components Fig 6 1 Item 10 Quantity 1 134 834 HOSE SAE 187 ID x 410 OD order by ft 3ft 2 149 332 CLAMP hose 405 485clp dia slfttng 2 3 GS1 125...

Page 29: ...ire x 1 125 2 2 000 069 TIP contact scr 045 wire x 1 125 2 3 169 728 ADAPTER contact tip 1 4 169 729 ADAPTER nozzle 1 5 170 467 RING retaining 1 6 170 468 O RING 1 7 169 730 WASHER shock 1 8 169 731 T...

Page 30: ...ner monocoil 023 025 wire x 15ft consisting of 1 24 172 258 KIT liner monocoil 030 035 wire x 15ft consisting of 1 24 172 259 KIT liner monocoil 035 045 wire x 15ft consisting of 1 25 079 975 O RING 1...

Page 31: ...ting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Spoolmate 250 Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as...

Page 32: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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