Page 2 - From Miller to You
Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearestdistributor or service agency call ...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
OM-225 311 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoi...
Page 6 - WELDING can cause fire or explosion.
OM-225 311 Page 2 Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld. ARC RAYS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil-ter lenses to protect...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; California Proposition 65 Warnings
OM-225 311 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system isproperly siz...
Page 9 - SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION; Symboles utilisés; Dangers relatifs au soudage à l’arc
OM-225 311 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro-cédure comporte...
Page 10 - peuvent
OM-225 311 Page 6 Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provo-quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS D’ARC peuvent entraî-ner de...
Page 11 - LIRE LES INSTRUCTIONS.; Proposition californienne 65 Avertissements
OM-225 311 Page 7 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO-SION. D Ne pas placer l’appareil sur, au-dessus ouà proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité deproduits inflammables. ...
Page 13 - SECTION 3 − SPECIFICATIONS; Specifications
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 9 SECTION 3 − SPECIFICATIONS 3-1. Specifications A. 115 VAC Model Rated Welding Output Amperage Range Maximum Open-Circuit Voltage DC Amperes Input at Rated Load Out- put 115 V, 60 Hz, Single-Phase KVA KW Weight W/ G...
Page 14 - Duty Cycle And Overheating; A or V
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 10 3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10minutes that unit can weld at ratedload without overheating. If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen min...
Page 15 - AMPERAGE
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 11 3-3. Volt-Ampere Curves The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding power source. Curvesof other settings fall between thecurves shown. 225 265-A / 228 ...
Page 16 - SECTION 4 − INSTALLATION; Installing Welding Gun; Installing Work Clamp
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 12 SECTION 4 − INSTALLATION 4-1. Installing Welding Gun Ref. 802 982-A / Ref. 801 987 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob. Insert gun endthrough opening until it bottomsagainst drive assembly. ...
Page 17 - Work Cable Routing Inside Unit; Changing Polarity
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 13 4-3. Work Cable Routing Inside Unit Ref. 802 982-A 1 Work Cable 2 Output Terminal Block Insert work cable through openingin front panel and route along backof front panel to output terminalblock. Close door. 2 1 4...
Page 18 - Installing Gas Supply
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 14 4-6. Installing Gas Supply Obtain gas cylinder and chain torunning gear, wall, or otherstationary support so cylindercannot fall and break off valve. 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve,and o...
Page 19 - Selecting A Location And Connecting Input Power For 115 VAC Model
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 15 4-7. Selecting A Location And Connecting Input Power For 115 VAC Model 1 Rating Label 2 Grounded Receptacle A 115 volt, 20 ampere individualbranch circuit protected by time-delayfuses or circuit breaker is require...
Page 20 - Selecting A Location And Connecting Input Power For 230 VAC Model
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 16 4-8. Selecting A Location And Connecting Input Power For 230 VAC Model Y Installation must meet all Na-tional and Local Codes − haveonly qualified persons makethis installation. Y Disconnect and lockout/tag-out in...
Page 21 - Electrical Service Guide For 230 VAC Model
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 17 4-9. Electrical Service Guide For 230 VAC Model 60 Hz Single Phase Input Voltage 230 Input Amperes At Rated Output 21.7 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 , Time-Delay 2 25 Normal Op...
Page 23 - -12. Removing MIG Gun From Welding Power Source
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 19 4-12. Removing MIG Gun From Welding Power Source Open Pressure Assembly . Hold wire tightly to keep itfrom unraveling. Rewind Wire Onto Spool, Fasten End Of Wire To Spool Cut Off End Of Wire Loosen Knob, Disconnec...
Page 24 - -13. Installing Optional Spool Gun Switch In Welding Power Source
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 20 4-13. Installing Optional Spool Gun Switch In Welding Power Source Ref. 804 984-A / 804 892-A Tools Needed: 1/4, 5/16 in 9/16 in Y Turn Off unit, and disconnectinput power. . For units prior to Serial No.LH210051N...
Page 26 - SECTION 5 − OPERATION
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 22 SECTION 5 − OPERATION 5-1. Controls For 115 VAC Model w/Auto-Set E 1 Wire Speed Control Turn control clockwise inside white scale(10-100) to increase wire feed speed. (seeweld parameter chart in welding powersourc...
Page 27 - Controls For 115 VAC Model
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 23 5-2. Controls For 115 VAC Model 1 Wire Speed Control Turn control clockwise to increase wirefeed speed. (see weld parameter chart inwelding power source or Section 5-4, 5-5,5-6, 5-7, or 5-8, as applicable). 2 Volt...
Page 28 - Controls For 230 VAC Model
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 24 5-3. Controls For 230 VAC Model 1 Wire Speed Control Turn control clockwise to increase wirefeed speed. (see weld parameter chart inwelding power source or Section 5-5, 5-4,5-6, 5-7 or 5-8, as applicable). 2 Volta...
Page 29 - Notes
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 25 Notes
Page 30 - Weld Parameter Chart For 115 VAC Model w/Auto−Set
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 26 5-4. Weld Parameter Chart For 115 VAC Model w/Auto−Set E IMPORTANT: Match drive roll groove to diameter of wire being used. Set Tension knob setting to 3 at start. Adjust tension per instructions in the manual. NO...
Page 31 - Manual Setup
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 27 227 931-H H Manual Setup Refer to chart below to select Voltage and Wire Speed basedon thickness of metal being welded. 2. Number on left of slash is VoltageKnob Setting. (Example: 4 / 65) 1. Number on right of sl...
Page 32 - slash is Voltage; Solid Wire; Selecting Wire, Gas and Control Settings for Aluminum
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 28 5-5. Weld Parameter Chart For 115 VAC Model w/Factory SetNon-Wire Speed Tracking Mode 1. Number on left of slash is Voltage Knob Setting. (Example: 4.5 / 65) 2. Number on right of slash is Wire Speed Knob Setting....
Page 33 - with optional Spool Gun, Order part no. 300371
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 29 224 940-D 3/30 3.5/45 2.5/28 2.5/35 3/30 3.5/45 4.5/35 5/22 5/405/30 5.5/455.5/30 4.5/40 4/55 2/302/256/50 8/65 6.5/40 5.5/80 5.5/50 5.5/50 6/40 7.5/85 7/70 10/9010/4510/6010/3010/45 8/40 10/32 10/8010/60 5/35 3.5...
Page 34 - Weld Parameter Chart For 115 VAC Model w/Wire Speed Tracking Mode; To enable wire speed tracking, proceed as follows:
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 30 5-6. Weld Parameter Chart For 115 VAC Model w/Wire Speed Tracking Mode 1. Number on left of slash is Voltage Knob Setting. (Example: 4.5/65) 2. Number on right of slash is Wire Speed Knob Setting. (Example: 4.5 / ...
Page 35 - To disable wire speed tracking, proceed as follows:
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 31 232 016-A 3/30 3.5/45 2.5/28 2.5/35 3/30 3.5/45 4.5/35 5/22 5/405/30 5.5/455.5/30 4.5/40 4/55 2/302/256/50 8/65 6.5/40 5.5/80 5.5/50 5.5/50 6/40 7.5/85 7/70 10/9010/4510/6010/3010/45 8/40 10/32 10/8010/60 5/35 3.5...
Page 36 - Stainless
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 32 5-7. Weld Parameter Chart For 230 VAC Model w/Factory SetNon-Wire Speed Tracking Mode .030” (0.8 mm).035” (0.9 mm) 1. Number on left ofslash is VoltageKnob Setting. (Example: 4.5 / 55) 2. Number on rightof slash i...
Page 38 - Weld Parameter Chart For 230 VAC Model w/Wire Speed Tracking Mode
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 34 5-8. Weld Parameter Chart For 230 VAC Model w/Wire Speed Tracking Mode 1. Number on left ofslash is VoltageKnob Setting. (Example: 4.5 / 65) 2. Number on rightof slash is WireSpeed Knob Setting. (Example: 4.5 / 65...
Page 40 - Routine Maintenance; A. Drive Motor Protection
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 36 SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more oftenduring severe conditions. n = Check Z = Change ~ = Clean l = Replace * To be done b...
Page 41 - Changing Drive Roll Or Wire Inlet Guide; Replacing Gun Contact Tip
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 37 6-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide Remove guide by pressing onbarbed area or cutting off one endnear housing and pulling it out ofhole. Push new guide into hole fromrear until it snaps...
Page 42 - Cleaning Or Replacing Gun Liner
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 38 6-6. Cleaning Or Replacing Gun Liner Ref. ST-802 399-A 8 mm / 10 mm Y Disconnect gun from unit. Tools Needed: Lay gun cable out straightbefore installing new liner. Head Tube 8 mm Remove liner. Remove nozzle, cont...
Page 44 - Troubleshooting Table
. A complete Parts List is available on-line at www.MillerWelds.com OM-225 311 Page 40 6-8. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fandoes not run. Secure power cord plug in receptacle (see Section 4-7 or 4-8). does not run. Replace building line fuse or reset circu...
Page 46 - SECTION 7 − ELECTRICAL DIAGRAM
OM-225 311 Page 42 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram
Page 48 - SECTION 8 − MIG WELDING (GMAW) GUIDELINES; Typical MIG Process Connections
OM-225 311 Page 44 SECTION 8 − MIG WELDING (GMAW) GUIDELINES 8-1. Typical MIG Process Connections Y Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible. Wire Feeder/ Power Source Workpiece Gun ...
Page 49 - Typical MIG Process Control Settings; NOTE
OM-225 311 Page 45 8-2. Typical MIG Process Control Settings These settings are guidelines only. Material and wire type, joint design, fitup,position, shielding gas, etc. affect settings. Test welds to be sure they comply tospecifications. NOTE 1/8 or .125 in Material thickness determines weldparame...
Page 50 - Holding And Positioning Welding Gun
OM-225 311 Page 46 8-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet andpressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle,and tip of wire is positioned correctly on seam. NOTE 1 Hold Gun and Control G...
Page 51 - Conditions That Affect Weld Bead Shape
OM-225 311 Page 47 8-4. Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle, direction of travel, electrode extension(stickout), travel speed, thickness of base metal, wire feed speed (weld current),and voltage. NOTE Short Normal Long Short Normal Long 10 ° 10 ° GUN ANGLES AN...
Page 52 - Gun Movement During Welding; Poor Weld Bead Characteristics
OM-225 311 Page 48 8-5. Gun Movement During Welding Normally, a single stringer bead is satisfactory for most narrow groove weld joints;however, for wide groove weld joints or bridging across gaps, a weave bead ormultiple stringer beads works better. NOTE 1 Stringer Bead − SteadyMovement Along Seam ...
Page 53 - Troubleshooting − Excessive Spatter; Troubleshooting − Porosity
OM-225 311 Page 49 8-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles thatcool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. ...
Page 55 - -14. Troubleshooting − Waviness Of Bead
OM-225 311 Page 51 8-13. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metalresulting in holes where no metal remains. S-0640 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase and/or mai...
Page 57 - SECTION 9 − PARTS LIST; Recommended Spare Parts; Quantity; Optional Drive Rolls; Options
OM-225 311 Page 53 SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Quantity Description Part No. Item No. 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦ 087 299 TIP, contact scr .023 wir...
Page 59 - (Equipment with a serial number preface of “LH” or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 2007−01 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Con...
Page 60 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters−USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European H...
