Miller 25- User Manual

OM-1326 Page 3 Return To Table Of Contents 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 sup...

OM-1326 Page 4 Return To Table Of Contents 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 Preparati...

OM-1326 Page 5 Revenez à la table des matières SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. »Cette procédure présente des risques identifiés par lessymboles adjacents aux directives. Y I...

OM-1326 Page 6 Revenez à la table des matières Le rayonnement de l’arc génère des rayons visibles etinvisibles intenses (ultraviolets et infrarouges) suscep-tibles de causer des brûlures oculaires et cutanées.Des étincelles sont projetées pendant le soudage. LES RAYONS DE L’ARC peuvent cau-ser des b...

OM-1326 Page 8 Revenez à la table des matières 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...

OM-1326 Page 9 Return To Table Of Contents SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Wire Feed Output X Duty Cycle Do Not Switch While Welding V Volts Increase On Off Gas Metal Arc Welding (GMAW) Gun Wire Feed Spool Gun Gas Input Gas Output Voltage Input Press To Reset U 0 Rated No-Load V...

OM-1326 Page 10 Return To Table Of Contents 4-2. Welding Power Source Duty Cycle And Overheating 4 Minutes Welding 6 Minutes Resting 6 Minutes Welding 4 Minutes Resting Duty Cycle is percentage of 10minutes that unit can weld at ratedload without overheating. If unit overheats, Thermistor (T)opens, ...

OM-1326 Page 11 Return To Table Of Contents 4-4. Volt-Ampere Curves ssb1.1 10/91 − 196 844 / S-0700 1 Normal Volt-Ampere Curves The volt-ampere curves show thenormal minimum and maximumvoltage and amperage outputcapabilities of the welding powersource. Curves of other settings fallbetween the curves...

OM-1326 Page 12 Return To Table Of Contents 4-7. Connecting A Spoolmatic R 15A Or 30A Gun The Spoolmatic 15A or 30A welding gun connects directly to the 10-pin receptacle on the front of the welding powersource − no adapter required. NOTE: Two welding guns may be connected to the welding power sourc...

OM-1326 Page 13 Return To Table Of Contents 4-9. Installing Gas Supply 802 028-A / Ref. 802 477-B Tools Needed: 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 ofvalve, and ope...

OM-1326 Page 14 Return To Table Of Contents 4-10. Installing Wire Spool And Adjusting Hub Tension When a slight force is neededto turn spool, tension is set. 15/16 in Use compression springwith 8 in (200 mm) spools. Tools Needed: 072573-B / 802 922 Installing 1 Or 2 lb Wire Spool To install either a...

OM-1326 Page 15 Return To Table Of Contents 4-12. Electrical Service Guide Input Voltage 200 230 400 460 575 Input Amperes At Rated Output 48 42 24 21 17 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker 1 , Time-Delay 2 60 50 30 25 20 Normal Operating 3 70 60 35 30 ...

OM-1326 Page 20 Return To Table Of Contents SECTION 5 − OPERATION 5-1. Controls Ref. 205 637 1 Voltage Control Turn control clockwise to increasevoltage. 2 Wire Speed Control Turn control clockwise to increase wirefeed speed. JOG Mode If the trigger on either gun is held formore than 3 seconds witho...

OM-1326 Page 21 Return To Table Of Contents 5-2. Voltmeter And Wire Feed Speed Meter Operation 1 Voltmeter 2 Wire Feed Speed Meter Power Up Status Both meters display 888 at unit power up. After one second, preset values appear onboth meters. The MIG gun settings (notspool gun) are always the defaul...

OM-1326 Page 22 Return To Table Of Contents SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more oftenduring severe conditions. 3 Months Replace unreadable labels Repair or replacecracked weld cable Clean and tighten weld termin...

OM-1326 Page 23 Return To Table Of Contents 6-4. Changing Drive Roll and Wire Inlet Guide 1 Securing Screw 2 Inlet Wire Guide Loosen screw. Slide tip as close todrive rolls as possible withouttouching. Tighten screw. 3 Anti-Wear Guide Install guide as shown. 4 Drive Roll The drive roll consists of t...

OM-1326 Page 24 Return To Table Of Contents 6-6. Cleaning Or Replacing Gun Liner Ref. 800 797-C 5/16 in, 10 mm To Reassemble Gun: Install and tighten new liner. Cut liner off 3/4 in (20 mm) (3/8 in[9.5 mm] for aluminum) from headtube. Install adapter, contact tip, andnozzle. Y Disconnect gun from un...

OM-1326 Page 25 Return To Table Of Contents 6-7. Replacing Switch And/Or Head Tube Ref. 800 795-C 1 Remove handlelocking nut. 2 Remove switch housing. Note: If installing newswitch, push switch lead connectors onto terminal ofnew switch (polarity is not important). Install switchback into handle, an...

OM-1326 Page 26 Return To Table Of Contents 6-8. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 4-13). Replace building line fuse or reset circuit breaker if open (see Section 4-13). Secure gun trigger connections (see Section 4-6...

OM-1326 Page 28 Return To Table Of Contents SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram

OM-1326 Page 30 Return To Table Of Contents 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/ Po...

OM-1326 Page 31 Return To Table Of Contents 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 3.5 x 125 A = 437 ipm 2 x 125 ...

OM-1326 Page 32 Return To Table Of Contents 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...

OM-1326 Page 33 Return To Table Of Contents 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 Slow FILLET WELD ELECTODE EXTENSIO...

OM-1326 Page 34 Return To Table Of Contents 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 − S...

OM-1326 Page 35 Return To Table Of Contents 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. Sel...

OM-1326 Page 36 Return To Table Of Contents 8-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallowfusion between weld metal andbase metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparati...

OM-1326 Page 37 Return To Table Of Contents 8-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not coverjoint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not...

OM-1326 Page 38 Return To Table Of Contents 8-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) ofshielding gases have been developed over the years. The most commonly used shielding gases are listed in thefollowin...

OM-1326 Page 40 Return To Table Of Contents SECTION 9 − PARTS LIST 803 008-B . Hardware is common andnot available unless listed. 20 21 23 15 16 14 13 12 22 4 5 6 10 11 7 8 9 19 2 1 − Fig 9 -2 17 − Fig 9 -4 3 − Fig 9 -6 18 − Fig 9 -3 Figure 9-1. Main Assembly

OM-1326 Page 49 Return To Table Of Contents 9-7. Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: 1 V-Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 U-Cogged rolls for extremely soft shelled wires (usual...

Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 8/03 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?Contac...

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