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OM-1308 Page 2

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.

ARC RAYS can burn eyes and skin.

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).

D

Wear approved safety glasses with side shields under your
helmet.

D

Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.

D

Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.

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.

WELDING can cause fire or explosion.

D

Protect yourself and others from flying sparks and hot metal.

D

Do not weld where flying sparks can strike flammable material.

D

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

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

D

Watch for fire, and keep a fire extinguisher nearby.

D

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

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).

D

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

Do not use welder to thaw frozen pipes.

D

Remove stick electrode from holder or cut off welding 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 lighter or matches,
from your person before doing any welding.

FLYING METAL can injure eyes.

D

Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.

D

Wear approved safety glasses with side
shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D

Shut off shielding gas supply when not in use.

D

Always ventilate confined spaces or use
approved air-supplied respirator.

HOT PARTS can cause severe burns.

D

Do not touch hot parts bare handed.

D

Allow cooling period before working on gun or
torch.

MAGNETIC FIELDS can affect pacemakers.

D

Pacemaker wearers keep away.

D

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

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D

Wear approved ear protection if noise level is
high.

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.

CYLINDERS can explode if damaged.

D

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

D

Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.

D

Keep cylinders away from any welding or other electrical circuits.

D

Never drape a welding torch over a gas cylinder.

D

Never allow a welding electrode to touch any cylinder.

D

Never weld on a pressurized cylinder – explosion will result.

D

Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.

D

Turn face away from valve outlet when opening cylinder valve.

D

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.

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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