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OM-116 Page 7

4-3.

Troubleshooting

Trouble

Remedy

No weld output; fan does not run.

Be sure line disconnect switch is in On position (see Section 2-3).

Check and replace line fuses if open. Reset breakers if necessary (see Section 2-3).

Fan does not run; weld output okay.

Be sure nothing is blocking movement of fan. If fan does not run 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 length. See User’s Guide also.

Reduce amperage setting (see Section 3-1).

Electrode freezing to work.

Use dry, properly stored electrodes. See User’s Guide also.

Increase arc length. See User’s Guide also.

Increase amperage setting (see Section 3-1).

SECTION 5 – ELECTRICAL DIAGRAM

SA-108 072

Figure 5-1. Circuit Diagram For Welding Power Source

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...

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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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