Miller Electric Millermatic 250 Owner's Manual
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Miller Electric Millermatic 250 Owner's Manual

Arc welding power source and wire feeder
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Millermatic 250
OM-1308
144 212N
March 1998
Processes
Gas Metal Arc (MIG) Welding
Flux Cored Arc (FCAW)
Welding
Description
Arc Welding Power Source And Wire
Feeder
R

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Summary of Contents for Miller Electric Millermatic 250

  • Page 1 OM-1308 144 212N March 1998 Processes Gas Metal Arc (MIG) Welding Flux Cored Arc (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Millermatic 250 Visit our website at www.MillerWelds.com...
  • Page 2 Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS The following terms are used interchangeably SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......throughout this manual: 1-1.

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    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. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols for Installation, Operation, and Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 9: Section 2 - Installation

    SECTION 2 – INSTALLATION 2-1. Specifications Max. Open- Amps Input at Rated Output, 50 or 60 Hz, Single-Phase Circuit 200 V 220 V 230 V 380 V 415 V 460 V 575 V Rated Output Voltage 250 A at 28 VDC, 200 A at 28 VDC, 40% Duty Cycle 60% Duty Cycle...

  • Page 10: Volt-Ampere Curves

    2-3. Volt-Ampere Curves Normal Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capa- bilities of the welding power source. Curves of other settings fall be- tween the curves shown. Overload Volt-Ampere Curves When unit is used beyond capacity, circuitry senses the overload and shuts down unit output.

  • Page 11: Installing Welding Gun

    2-5. Installing Welding Gun Drive Assembly Gun Securing Knob Gun End Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly. Tighten knob. Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Close door. Ref.

  • Page 12: Installing Wire Spool And Adjusting Hub Tension

    2-8. Installing Wire Spool And Adjusting Hub Tension Use compression spring with 8 in (200 mm) spools. When a slight force is needed to turn spool, tension is set. Tools Needed: 15/16 in ST-072573-B 2-9. Positioning Jumper Links Check input voltage available at site.

  • Page 13: Electrical Service Guide

    2-10. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length 93 (28) 75 (23) 82 (25) 137 (42) 163 (50) 329 (100) 313 (95)

  • Page 14: Threading Welding Wire

    2-12. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. 4 in 6 in (102 mm) (150 mm) Open pressure assembly.

  • Page 15: Section 3 - Operation

    SECTION 3 – OPERATION 3-1. Controls Wire Speed Control The scale around the control is per- cent, not wire feed speed. Voltage Switch The scale around the control is actual voltage. Low Range/Full Range Switch Use Low Range when wire speed is between 50 and 350 ipm.

  • Page 16: Section 4 - Maintenance And Troubleshooting

    SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Repair or replace Replace unreadable labels. cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. during Remove drive roll and heavy service clean monthly.

  • Page 17: Replacing Gun Contact Tip

    4-4. Replacing Gun Contact Tip Y Turn Off power. Nozzle Contact Tip Cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. Tools Needed: ST-149 326-B 4-5. Changing Drive Roll And Wire Inlet Guide Securing Screw Inlet Wire Guide Loosen screw.

  • Page 18: Cleaning Or Replacing Gun Liner

    4-8. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun first. 3/8 in Head tube Remove nozzle, contact tip, adapter, and wire outlet guide. Wire Outlet Guide 3/8 in Remove liner. Lay gun cable out straight before installing new liner. Blow out gun casing.

  • Page 19: Replacing Switch And/Or Head Tube

    4-9. Replacing Switch And/Or Head Tube Y Disconnect gun first. Slide handle. Remove handle Remove switch housing. Note: If installing new locking nut. switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to end of figure.

  • Page 20: Troubleshooting

    4-10. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-11). Replace building line fuse or reset circuit breaker if open (see Section 2-11). Reset circuit breaker CB1 (see Section 4-2). Secure gun trigger connections (see Section 2-5).

  • Page 21: Section 5 - Electrical Diagram

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

  • Page 22: Parts View

    SECTION 6 – PARTS LIST Hardware is common and not available unless listed. ST-801 717 Figure 6-1. Main Assembly OM–1308 Page 18...
  • Page 23 Item Dia. Part Mkgs. Description Quantity Figure 6-1. Main Assembly ....148 597 . . . COUPLER, rod threaded .312-18 x 1.000 ......

  • Page 24: Baffle, Center W/Components

    Hardware is common and not available unless listed. Fig 6-4 ST-148 325-D Figure 6-2. Baffle, Center w/Components OM–1308 Page 20...
  • Page 25 Item Dia. Part Mkgs. Description Quantity Figure 6-2. Baffle, Center w/Components (Fig 6-1 Item 4) ....058 427 . . . RING, retaining spool ..........
  • Page 26 Item Dia. Part Mkgs. Description Quantity Figure 6-3. Panel, Front w/Components (Fig 6-1 Item ....175 840 CONTROL PANEL, (consisting of) ........
  • Page 27 Item Dia. Part Mkgs. Description Quantity Figure 6-4. Wire Drive And Gears (Fig 6-2 Item 34) ....602 009 . . . SCREW, .250-20 x 1.25 soc hd gr 8 .
  • Page 28 Table 6-1. Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: V-Grooved rolls for hard wire. U-Grooved rolls for soft and soft shelled cored wires. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). V-Knurled rolls for hard shelled cored wires.
  • Page 29 Item Part Description Quantity Figure 6-6. M-25 Gun (Fig 6-1 Item 25) ..169 724 NOZZLE, slip type .500 orf .125 recess ........
  • Page 30 Item Part Description Quantity Figure 6-6. M-25 Gun (Fig 6-1 Item 25) (Continued) ..169 737 HANDLE ..............
  • Page 31 Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT & PLAZCUT Model Plasma Cutting below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold...

  • Page 32: Options And Accessories

    FAX: 44 (0) 1204-598066 www.MillerWelds.com Contact the Delivering Carrier for: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00...

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