Miller Electric 225 Owner's Manual
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Miller Electric 225 Owner's Manual

Arc welding power source
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Thunderbolt XL
OM-316
August 2004
Processes
Description
AC/DC, 300/200 AC/DC Models:
225 And 300 Models:
Arc Welding Power Source
AC/DC, 300/200 AC/DC, 225, And 300
087 083Q
Stick (SMAW) Welding
R

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  • Page 1 Thunderbolt XL Visit our website at www.MillerWelds.com OM-316 August 2004 Processes Stick (SMAW) Welding Description AC/DC, 300/200 AC/DC Models: 225 And 300 Models: Arc Welding Power Source AC/DC, 300/200 AC/DC, 225, And 300 087 083Q...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. 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

    ..............4-8. Internal Connections For Operating 115/230 Volts, 225 Amperes AC And AC/DC Models From 115 Volts .

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 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. 1-2.
  • Page 6 ARC RAYS can burn eyes and skin. 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. 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).

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

    D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cause injury.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W.

  • Page 9: Section 2 − Consignes De Sécurité − À Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Y Identifie un message de sécurité particulier. Signifie «...
  • Page 10 LES RAYONS DE L’ARC peuvent cau- ser des brûlures oculaires et cuta- nées. Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) suscep- tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. D Porter un masque de soudage muni d’un filtre de la nuance adéquate pour se protéger le visage et les yeux pendant le soudage ou pour re- garder (voir les normes de sécurité...

  • Page 11: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil

    2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- SION D Ne pas placer l’appareil sur une surface inflam- mable, ni au−dessus ou à proximité d’elle. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique −...

  • Page 12: Principales Normes De Sécurité

    2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, norme American Welding Society AWS F4.1, de l’American Welding Society, 550 N.W.

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Amperes Alternating Current Welding Arc 3-2. Manufacturer’s Rating Labels Rating Label For EN/FR Machines LR5071 EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY TOUTE ALTÉRATION DE L’ÉTIQUETTE ANNULLE LA GARANTIE Do Not Switch Single Phase Under Load Output Electrode Positive...

  • Page 14: Section 4 − Installation

    Amperage Rated Welding Output Rated Welding Output Range Range 225 A @ 25 Volts AC, 20% Low: 30 − 150A Duty Cycle @ 60 Hz; High: 40 − 235A 15% Duty Cycle @ 50 Hz 300 A @ 30 Volts AC, Low: 40 −...

  • Page 15: Duty Cycle Charts

    *These models have a 15% duty cycle when used with 50 Hz input power. Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Y 20% Duty Cycle at 225 Amperes. Ex- ceeding duty cycle can damage unit and void warranty. 8 Minutes Resting B.

  • Page 16: Volt-Ampere Curves

    4-3. Volt-Ampere Curves A. For AC/DC Models A. For 115/230, 230 And 460 Volt Models (225/150 Amperes) AC Amperes B. For 220, 230/400, And 460 Volt Models (300/200 Amperes) AC Amperes OM-316 Page 12 A=LOW RANGE B=HIGH RANGE The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities.
  • Page 17 B. For AC Models A. For 115/230 And 230 Volt Models (225 Amperes) AC Amperes B. For 220 Volt Model (300 Amperes) AC Amperes A=LOW RANGE B=HIGH RANGE C. For 230/400 Volt Model (300 Amperes) The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities.

  • Page 18: Selecting A Location

    4-4. Selecting A Location 18 in (457 mm) for airflow OM-316 Page 14 LR5071 EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY TOUTE AL TÉRATION DE L ’ÉTIQUETTE ANNULLE LA GARANTIE Rating Label (See Section 3-2) Locate unit near correct input power. Y Special installation may be required where gasoline or volatile liquids are present −...

  • Page 19: Installing Electrode Holder And Work Clamp

    4-5. Installing Electrode Holder And Work Clamp Tools Needed: 1/2 in 1/4 in 4-6. Weld Output Cables NOTE For weld output cable replacements or extensions, contact your Factory Authorized Service Agent. Y Turn Off unit and disconnect input power before installing electrode holder or work clamp.

  • Page 20: Electrical Service Guide

    4-7. 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 In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil [ ] Electrical Service Requirements For 300/200 AC/DC And 300 AC Models Reference: 1997 National Electrical Code (NEC) OM-316 Page 16...

  • Page 21: Internal Connections For Operating 115/230 Volts, 225 Amperes Ac And Ac/Dc Models From 115 Volts

    4-8. Internal Connections For Operating 115/230 Volts, 225 Amperes AC And AC/DC Models From 115 Volts NOTE Follow applicable electrical codes and have a competent electrician make internal connections. Note the input amperes as stated in Section 4-7. To Fan...

  • Page 22: Internal Connections For Operating 230/400 Volts, 300/200 Amperes Ac/Dc Or 300 Amperes Ac Models From 230 Volts

    4-9. Internal Connections For Operating 230/400 Volts, 300/200 Amperes AC/DC Or 300 Amperes AC Models From 230 Volts NOTE Follow applicable electrical codes and have a competent electrician make internal connections. Note the input amperes as stated in Section 4-7. Connected For 400 Volts Connected For 230 Volts OM-316 Page 18...

  • Page 23: Connecting Input Power

    4-10. Connecting Input Power =GND/PE Earth Ground Ref. 802 246 For Models Supplied With Plug Y Disconnect and lockout/tag- out input power before instal- ling receptacle. Y Have only qualified persons make this installation. See rating label in Section 4-4, and be sure to supply correct in- put power.

  • Page 24: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls A. Controls For AC/DC Models OM-316 Page 20 Amperage Adjustment Control Power Switch Mode Switch For DC Weld Output Use mode switch to select polarity of dc output, Electrode Posi- tive/DCEP (+),or Electrode Nega- tive/DCEN (−).
  • Page 25 B. Controls For AC Models Amperage Adjustment Control Power Switch Mode Switch Use mode switch to select ac low range or high range output. Ref. 218 237-A / 802 105-C OM-316 Page 21...

  • Page 26: Section 6 − Maintenance & Troubleshooting

    SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance 6 Months Blow Out Or Vacuum During Heavy Service, 6-2. Lubricating Shunt Block And Anti-Noise Adjustment Tools Needed: 1/2 in 5/16 in OM-316 Page 22 Y Disconnect power before maintaining. 3 Months Replace Unreadable Labels...

  • Page 27: Reinstalling Amperage Adjustment Indicator

    6-3. Reinstalling Amperage Adjustment Indicator Proper alignment of pointer and crank handle. For 225 A models, X = 2−1/2 in For 300 A models, X = 2−3/8 in Viewed from right side of unit. Tools Needed: Y Turn Off welding power source and disconnect input power.

  • Page 28: Troubleshooting

    6-4. Troubleshooting Trouble No weld output; fan does not run. Be sure line disconnect switch is in On position (see Section 4-10). Check and replace line fuses if open. Reset breakers if necessary (see Section 4-10). Fan does not run; weld output okay. Be sure nothing is blocking movement of fan.

  • Page 29: Section 7 − Electrical Diagrams

    SECTION 7 − ELECTRICAL DIAGRAMS 191 364 Figure 7-1. Circuit Diagram For AC/DC (230 Volts) Models 191 365 Figure 7-2. Circuit Diagram For AC/DC (460 Volts) Models OM-316 Page 25...
  • Page 30 CONNECTED FOR 230 VOLTS PLG1 WORK Figure 7-3. Circuit Diagram For AC/DC (115/230 Volts) Models VOLT ONLY POWER CORD WORK Figure 7-4. Circuit Diagram For 300/200 AC/DC (220 Volts) Models OM-316 Page 26 NEUTRAL (WHT) LINE (BLK) PLG1 ELECTRODE S.O.P. S.O.P.
  • Page 31 CONNECTED FOR 400 VOLTS POWER CORD WORK Figure 7-5. Circuit Diagram For 300/200 AC/DC (230/400 Volts) Models VOLT ONLY POWER CORD WORK Figure 7-6. Circuit Diagram For 300/200 AC/DC (460 Volts) Model 230V ELECTRODE 230V S.O.P. S.O.P. ELECTRODE CONNECTED FOR 230 VOLTS OM-316 Page 27 191 369 191 370...
  • Page 32 VOLT ONLY PLG1 Figure 7-7. Circuit Diagram For 225 (230 Volts) Models CONNECTED FOR 230 VOLTS PLG1 WORK Figure 7-8. Circuit Diagram For 225 (115/230 Volts) Models OM-316 Page 28 AC HIGH AC LOW WORK NEUTRAL (WHT) LINE (BLK) PLG1...
  • Page 33 VOLT ONLY POWER CORD S.O.P. AC HIGH AC LOW WORK ELECTRODE 191 366 Figure 7-9. Circuit Diagram For 300 (220 Volts) Models CONNECTED FOR 400 VOLTS CONNECTED FOR 230 VOLTS 230V POWER CORD WORK ELECTRODE 191 367 Figure 7-10. Circuit Diagram For 300 (230/400 Volts) Models OM-316 Page 29...

  • Page 34: Section 8 − Welding Methods & Troubleshooting

    SECTION 8 − WELDING METHODS & TROUBLESHOOTING A. Welding Methods 8-1. Shielded Metal Arc Welding (SMAW) Procedure Tools Needed: Workpiece Make sure workpiece is clean before welding. Work Clamp Place as close to the weld as possible. Electrode A small diameter electrode requires less current than a large one. Follow recommendations of electrode manufacturer when setting weld amperage (see 8-2).

  • Page 35: Electrode And Amperage Selection Chart

    8-2. Electrode And Amperage Selection Chart 3/32 6010 5/32 & 3/16 6011 7/32 1/16 5/64 3/32 6013 5/32 3/16 7/32 3/32 7014 5/32 3/16 7/32 3/32 5/32 7018 3/16 7/32 3/32 5/32 7024 3/16 7/32 3/32 Ni-Cl 5/32 3/16 3/32 308L 5/32 6010...

  • Page 36: Striking An Arc

    8-3. Striking An Arc Scratch Start Technique Tap Start Technique 8-4. Positioning The Electrode Holder End View Of Work Angle End View Of Work Angle OM-316 Page 32 10 −30 Side View Of Electrode Angle 10 −30 Side View Of Electrode Angle Electrode Workpiece Drag electrode across workpiece...

  • Page 37: Weld Bead Characteristics

    8-5. Weld Bead Characteristics Poor Weld Bead Good Weld Bead 8-6. Conditions That Affect Weld Bead Shape Electrode Angle Angle Too Small Arc Length Too Short Travel Speed Slow Correct Angle Drag Normal Normal Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration...

  • Page 38: Electrode Movement During Welding

    8-7. Electrode Movement During Welding 8-8. Butt Joints OM-316 Page 34 1/16 in (1.6 mm) Stringer Bead − Steady Move- ment Along Seam Weave Bead − Side To Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode.

  • Page 39: Lap Joints

    8-9. Lap Joints 30 Or Less Single-Layer Fillet Weld 8-10. Tee Joints Or Less B. Welding Troubleshooting Possible Causes Arc length too long. Reduce arc length. Damp electrode. Use dry electrode. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding.
  • Page 40 Possible Causes Amperage too high for electrode. Decrease amperage or select larger electrode. Arc length too long or voltage too high Reduce arc length or voltage. Possible Causes Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
  • Page 41 Excessive Penetration Possible Causes Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. Possible Causes Excessive heat input. Select lower amperage. Use smaller electrode with lower amperage. Increase and/or maintain steady travel speed. Possible Causes Unsteady hand.

  • Page 42: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 802 245-E Figure 9-1. Main Assembly (AC/DC model illustrated) OM-316 Page 38...
  • Page 43 210 309 +WRAPPER ..190 079 SWITCH, secondary 2-position (AC 225 model) & (AC 300 model) ..190 080 SWITCH, secondary 4-position (AC/DC 225 model) & (AC/DC 300 model) .
  • Page 44 Notes...
  • Page 45 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
  • Page 46 Notes Invision 354MP TM-188 304 Page 2...
  • Page 47 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after for your local the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 48: Owner's Record

    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. 2004 Miller Electric Mfg. Co. 1/04 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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