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OM-116 Page 2

CYLINDERS can explode if damaged.

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.

1.

Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.

2.

Keep cylinders away from any welding or other electrical circuits.

3.

Never drape an electrode holder over a gas cylinder.

4.

Never allow a welding electrode to touch any cylinder.

5.

Never weld on a pressurized cylinder – explosion will result.

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.

1.

Protect yourself and others from flying sparks and hot metal.

2.

Do not weld where flying sparks can strike flammable material.

3.

Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.

4.

Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.

5.

Watch for fire, and keep a fire extinguisher nearby.

6.

Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.

7.

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).

8.

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.

9.

Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder when not in use.

11. Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

12. Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

1-3.

Additional Installation, Operation, And Maintenance Hazards

FIRE OR EXPLOSION can result from
placing unit on, over, or near
combustible surfaces.

1.

Do not install unit on, over, or near combustible
surfaces or flammables.

HOT PARTS can cause severe burns.

1.

Do not touch hot parts bare handed. Allow cooling
period before beginning.

MAGNETIC FIELDS FROM HIGH
CURRENTS can affect pacemaker
operation.

1.

Wearers should consult their doctor before going
near arc welding, gouging, or spot welding
operations.

FLYING PIECES OF METAL or DIRT can
injure eyes.

1.

Wear safety glasses with side shields or face
shield.

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

Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and
Cutting 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

National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.

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.

Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5.

EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields

The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields – Background
Paper
, OTA-BP-E-53 (Washington, DC: U.S. Government Printing
Office, May 1989): “. . . there is now a very large volume of scientific
findings based on experiments at the cellular level and from studies
with animals and people which clearly establish that low frequency
magnetic fields can interact with, and produce changes in, biological
systems. While most of this work is of very high quality, the results are
complex. Current scientific understanding does not yet allow us to
interpret the evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear science-based advice on
strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following
procedures:

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 the body.

4.

Keep welding power source and cables as far away as
practical.

5.

Connect work clamp to workpiece as close to the weld as
possible.

About Pacemakers:

The above procedures are also recommended for pacemaker
wearers. Consult your doctor for complete information.

Summary of Contents for Thunderbolt 225

Page 1: ...ce For SMAW Stick Welding Rated Welding Output Amperage Range Maximum Open Circuit Amperes Input at Rated Load Output 60 Hz Single Phase Overall Dimensions Weight Output Voltage 230 V KW 225 A 25 Volt...

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: ...f earth grounding of the workpiece is required ground it directly with a separate cable do not use work clamp or work cable 13 Do not touch electrode if you are in contact with the work ground or anot...

Page 4: ...t their doctor before going near arc welding gouging or spot welding operations FLYING PIECES OF METAL or DIRT can injure eyes 1 Wear safety glasses with side shields or face shield 1 4 Principal Safe...

Page 5: ...ace hands where shown to move unit Get help when moving unit 2 Running Gear Mounting Holes 3 Rating Label Locate unit near correct input power 4 Amperage Adjustment Rod 5 Handle 6 Pin Install as shown...

Page 6: ...GND PE Connect First Minimum input and grounding conductor size is 10 AWG Kcmil not to exceed 87 ft 26 m in length Install conductors in conduit or equivalent into a deenergized line disconnect devic...

Page 7: ...Receptacle 6 Power Switch 1 2 6 3 4 5 2 Minutes Welding 8 Minutes Resting 3 2 Duty Cycle Chart And Volt Ampere Curves rduty1 5 95 ST 001 836 A ST 001 844 A Duty Cycle is percentage of 10 minutes that...

Page 8: ...r source and disconnect input power 1 Shunt Block Apply light coating of high tempera ture grease to shaded areas of both shunt blocks Install amperage control handle and locking pin Turn handle to sp...

Page 9: ...freely replace fan motor Erratic weld current Clean and tighten all weld cable connections Erratic arc with excessive spatter Use dry properly stored electrodes See User s Guide also Shorten arc leng...

Page 10: ...lief 240 510 ID x 875mtg hole 1 10 088 297 CORD SET 250V 6 50P 12ga 3 c 6ft 1 11 039 778 RECEPTACLE str 2P3W 50A 250V 1 12 005 656 BLADE fan 6 in 4wg 30deg 175 bore CW 1 13 FM 123 468 MOTOR 230V 50 60...

Page 11: ...D x 500 1 14 020 284 WEDGE coil 1 15 010 653 BEARING thr oil imprg 375 ID x 750 OD x 062 1 16 010 929 WASHER flat stl spr 375 1 17 024 869 COLLAR set w screws consisting of 1 18 024 612 COLLAR set 1 1...

Page 12: ...4 95 OPTIONS AND ACCESSORIES No 11A RUNNING GEAR 041 637 A handle and two wheels with solid rubber tires mount easily to the frame of the Thunderbolt 225 providing convenient portability...

Page 13: ......

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Page 15: ...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 16: ...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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