Miller-electric 225 User Manual Page 1

AC/DC, 300/200 AC/DC, 225, And 300ProcessesDescriptionArc Welding Power SourceOM-316 087 083QAugust 2004Thunderbolt XLRStick (SMAW) Welding225 And 300

OM-316 Page 6Le rayonnement de l’arc génère des rayons visibles etinvisibles intenses (ultraviolets et infrarouges) suscep-tibles de causer des brûlur

OM-316 Page 72-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien del’appareil.Risque D’INCENDIE OU D’EXPLO-SIOND Ne pas

OM-316 Page 82-4. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,de l’American Welding Society, 550

OM-316 Page 9SECTION 3 − DEFINITIONS3-1. Symbols And DefinitionsAAmperes Single PhaseDo Not SwitchUnder LoadInputOn Off OutputHzHertzAlternatingCurren

OM-316 Page 10SECTION 4 − INSTALLATION4-1. SpecificationsAC/DC ModelsModeRated WeldingOutputAmperageRangeMaximumOpen-CircuitAmperes Input at Rated Loa

OM-316 Page 114-2. Duty Cycle ChartsA. For AC/DC Models2 Minutes Welding 8 Minutes Resting086 727 / 099 602-ADuty Cycle is percentage of 10 minutestha

OM-316 Page 124-3. Volt-Ampere CurvesA. For AC/DC Models193 509 / 193 510 / 193 511 / 193 512The volt-ampere curves show theminimum and maximum voltag

OM-316 Page 13B. For AC Models193 508 / 193 513 / 193 511The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities.Cu

OM-316 Page 144-4. Selecting A Location217 652-A / 802 1051 Rating Label (See Section3-2)Locate unit near correct inputpower.Y Special installation m

OM-316 Page 154-5. Installing Electrode Holder And Work Clamp802 251 / 802 105-CY Turn Off unit and disconnectinput power before installingelectrode h

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-316 Page 164-7. Electrical Service GuideInput Voltage115 220 230 400 460Input Amperes At Rated Output95 [70]47.5[67][39]23.7[34]Max Recommended Sta

OM-316 Page 174-8. Internal Connections For Operating 115/230 Volts, 225 Amperes AC And AC/DCModels From 115 VoltsFollow applicable electrical codes a

OM-316 Page 184-9. Internal Connections For Operating 230/400 Volts, 300/200 Amperes AC/DC Or 300Amperes AC Models From 230 VoltsFollow applicable ele

OM-316 Page 194-10. Connecting Input PowerRef. 802 246For Models Supplied With PlugY Disconnect and lockout/tag-out input power before instal-ling rec

OM-316 Page 20SECTION 5 − OPERATION5-1. ControlsA. Controls For AC/DC ModelsRef. 217 857-B / 802 105-C1 Amperage Adjustment Control2 Power Switch3 Mod

OM-316 Page 21B. Controls For AC ModelsRef. 218 237-A / 802 105-C1 Amperage Adjustment Control2 Power Switch3 Mode SwitchUse mode switch to select ac

OM-316 Page 22SECTION 6 − MAINTENANCE & TROUBLESHOOTING6-1. Routine MaintenanceY Disconnect power before maintaining.3 MonthsReplaceUnreadableLabe

OM-316 Page 236-3. Reinstalling Amperage Adjustment IndicatorRef. 218 237-A / 802 248-CY Turn Off welding powersource and disconnect inputpower.1 Wrap

OM-316 Page 246-4. TroubleshootingTrouble RemedyNo weld output; fan does not run. Be sure line disconnect switch is in On position (see Section 4-10).

OM-316 Page 25SECTION 7 − ELECTRICAL DIAGRAMS191 364Figure 7-1. Circuit Diagram For AC/DC (230 Volts) Models191 365Figure 7-2. Circuit Diagram For AC/

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbo

OM-316 Page 26191 363-ASECT1S2WORK ELECTRODERZ1SR1CONNECTED FOR 230 VOLTSPRIGRNS11 23 4CONNECTED FOR 115 VOLTSPRIT11234PLG1FMFMS1GRNS1PLG1LINE(BLK)NEU

OM-316 Page 27191 369SECS2WORK ELECTRODERZ1SR1CONNECTED FOR 400 VOLTSPRIT1GRNS1230V1234 4CONNECTED FOR 230 VOLTSPRIT1132POWERCORDFMFMFigure 7-5. Circu

OM-316 Page 28191 362WORK230PRISECT1GRNVOLTONLYS2AC HIGHAC LOWELECTRODEPLG1FMS1Figure 7-7. Circuit Diagram For 225 (230 Volts) Models191 361-AWORKCONN

OM-316 Page 29WORK220PRISECT1S.O.P.GRNVOLTONLYS2AC HIGHAC LOWELECTRODEPOWERCORDFMS1191 366Figure 7-9. Circuit Diagram For 300 (220 Volts) Models191 36

OM-316 Page 30SECTION 8 − WELDING METHODS & TROUBLESHOOTINGmod5.1* 9/92A. Welding Methods8-1. Shielded Metal Arc Welding (SMAW) Procedure151 5931

OM-316 Page 318-2. Electrode And Amperage Selection ChartRef. 087 985-A3/321/85/323/167/321/41/165/643/321/85/323/167/321/43/321/85/323/167/321/43/321

OM-316 Page 328-3. Striking An ArcS-0049 / S-00501 Electrode2 Workpiece3 ArcDrag electrode across workpiecelike striking a match; lift electrodeslight

OM-316 Page 338-5. Weld Bead CharacteristicsRef. S-0052-B1 Large Spatter Deposits2 Rough, Uneven Bead3 Slight Crater During Welding4 Bad Overlap5 Poor

OM-316 Page 348-7. Electrode Movement During WeldingS-0054-A1 Stringer Bead − Steady Move-ment Along Seam2 Weave Bead − Side To SideMovement Along Sea

OM-316 Page 358-9. Lap JointsS-0063 / S-00641 Electrode2 Single-Layer Fillet WeldMove electrode in circular motion.3 Multi-Layer Fillet WeldWeld a sec

OM-316 Page 36Table 6-2. Excessive SpatterExcessive Spatter − scattering of moltenmetal particles that cool to solid form nearweld bead.Possible Cause

OM-316 Page 37Table 6-5. Excessive PenetrationGood PenetrationExcessive Penetration − weld metal melt-ing through base metal and hanging un-derneath w

OM-316 Page 38SECTION 9 − PARTS LIST802 245-E. Hardware is common andnot available unless listed.31Figure 9-1. Main Assembly (AC/DC model illustrated)

OM-316 Page 39DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-1. Main AssemblyQuantity1 134 464 LABEL, warning general precautionary static&wire fe 1.

Notes

NotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

TM-188 304 Page 2Invision 354MPNotes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/04Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-316 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _8/031-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith this

OM-316 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks

OM-316 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or

OM-316 Page 41-5. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from American Welding Society, 550 N

OM-316 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANTUTILISATIONsom_fre 8/032-1. Signification des symbolesSignifie « Mise en garde. Faire pre