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Miller Electric Millermatic 250X Owner's Manual

Arc welding power source and wire feeder
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Millermatic 250X
OM-1319
188 913M
October 2000
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
R

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Summary of Contents for Miller Electric Millermatic 250X

  • Page 1 OM-1319 188 913M October 2000 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 250X 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 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.

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

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: Section 2 - Installation

    SECTION 2 – INSTALLATION 2-1. Specifications Max. Open- Amps Input at Rated Output, 50 or 60 Hz, Single-Phase Rated Output Circuit 200 (208) V 230 V 400 V 460 V 575 V Voltage 250 A at 28 VDC, 200 A at 28 VDC, 40% Duty Cycle 60% Duty Cycle 2.3*...

  • Page 14: 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. ssb1.1 10/91 – SB-188 912 / S-0700 2-4.

  • Page 15: 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 (make sure gun end does not touch drive rolls). Tighten knob. Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar.

  • Page 16: Installing Gas Supply

    2-8. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other station- ary support so cylinder cannot fall and break off valve. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve.

  • Page 17: Positioning Jumper Links

    2-10. Positioning Jumper Links Check input voltage available at site. 230 VOLTS Jumper Links Access Door Open door. 200 VOLTS Jumper Link Label 460 VOLTS Check label – only one is on unit. Input Voltage Jumper Links Move jumper links to match input 230 VOLTS 575 VOLTS voltage.

  • Page 18: Selecting A Location And Connecting Input Power

    2-12. Selecting A Location And Connecting Input Power Rating Label Supply correct input power. Plug (NEMA Type 6-50P) Receptacle (NEMA Type 6-50R) Connect plug to receptacle. Input And Grounding 18 in (457 mm) of Y Do not move or operate unit Conductors space for airflow where it could tip.

  • Page 19: Threading Welding Wire

    2-13. 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. 6 in (150 mm) Open pressure assembly.

  • Page 20: Section 3 - Operation

    SECTION 3 – OPERATION 3-1. Controls Voltage Control Turn control clockwise to increase voltage. Scale around control is ac- tual voltage. Wire Speed Control Turn control clockwise to increase wire feed speed. Scale around con- trol is actual wire feed speed. Power Switch Pilot Light Ref.

  • Page 21: Weld Parameter Table

    3-2. Weld Parameter Table OM-1319 Page 17...

  • Page 22: Section 4 - Maintenance &Troubleshooting

    SECTION 4 – MAINTENANCE &TROUBLESHOOTING 4-1. Routine Maintenance Maintain more often Y Disconnect power during severe conditions. before maintaining. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals 6 Months Remove drive roll and Blow out or vacuum inside.

  • Page 23: Changing Drive Roll And Wire Inlet Guide

    4-4. Changing Drive Roll and Wire Inlet Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. Anti-Wear Guide Install guide as shown. Drive Roll Install correct drive roll for wire size and type.

  • Page 24: Troubleshooting

    4-6. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-12). Replace building line fuse or reset circuit breaker if open (see Section 2-12). Reset circuit breaker CB1 (see Section 4-2). Secure gun trigger connections (see Section 2-5).

  • Page 25: Section 5 - Electrical Diagram

    SECTION 5 – ELECTRICAL DIAGRAM 188 901-A Figure 5-1. Circuit Diagram OM-1319 Page 21...

  • Page 26: Section 6 - Parts List

    SECTION 6 – PARTS LIST Hardware is common and not available unless listed. Ref. 802 059 Figure 6-1. Main Assembly OM–1319 Page 22...
  • Page 27 Item Dia. Part Mkgs. Description Quantity Figure 6-1. Main Assembly ....Fig 6-2 . . . BAFFLE, center w/components ........
  • Page 28 Hardware is common and not available unless listed. ST-802 060-A Figure 6-2. Baffle, Center w/Components OM–1319 Page 24...
  • Page 29 Item Dia. Part Mkgs. Description Quantity Figure 6-2. Baffle, Center w/Components (Fig 6-1 Item 1) ....058 427 . . . RING, retaining spool ..........
  • Page 30 Item Dia. Part Mkgs. Description Quantity Figure 6-3. Panel, Front w/Components (Fig 6-1 Item 15) ....+188 711 PANEL, front control ..........
  • Page 31 Item Dia. Part Mkgs. Description Quantity Figure 6-4. Wire Drive And Gears (Fig 6-2 Item 26) ....602 009 . . . SCREW, .250-20 x 1.25 soc hd gr 8 .
  • Page 32 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 33 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 34: 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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