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OM-1308 Page 1

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_5/97

1-1.

Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

Y

Marks a special safety message.

.

Means “Note”; not safety related.

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.

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.

Y

Only qualified persons should install, operate, maintain, and
repair this unit.

Y

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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

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
grounded equipment is a hazard.

D

Do not touch live electrical parts.

D

Wear dry, hole-free insulating gloves and body protection.

D

Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.

D

Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.

D

Use AC output ONLY if required for the welding process.

D

If AC output is required, use remote output control if present on
unit.

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).

D

Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.

D

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
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 bare wiring –
replace cord immediately if damaged – bare wiring can kill.

D

Turn off all equipment when not in use.

D

Do not use worn, damaged, undersized, or poorly spliced cables.

D

Do not drape cables over your body.

D

If earth grounding of the workpiece is required, ground it directly
with a separate cable – do not use work clamp or work cable.

D

Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.

D

Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.

D

Wear a safety harness if working above floor level.

D

Keep all panels and covers securely in place.

D

Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.

D

Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.

D

Do not connect more than one electrode or work cable to any
single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.

D

Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

FUMES AND GASES can be hazardous.

D

Keep your head out of the fumes. Do not breathe the fumes.

D

If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.

D

If ventilation is poor, use an approved air-supplied respirator.

D

Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.

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.

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

Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.

Содержание Millermatic 250

Страница 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...

Страница 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...

Страница 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...

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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