Miller Electric Millermatic 250 Owner's Manual

ProcessesDescriptionGas Metal Arc (MIG) WeldingFlux Cored Arc (FCAW)WeldingArc Welding Power Source and WireFeederOM-1315 January 1997Eff. w/Serial Nu

OM-1315 Page 62-3. Volt-Ampere Curvesssb1.1 10/91 – SB-144 925 / S-07001 Normal Volt-Ampere CurvesThe volt-ampere curves show thenormal minimum and ma

OM-1315 Page 72-5. Installing Welding GunRef. ST-150 256-D1 Drive Assembly2 Gun Securing Knob3 Gun EndLoosen securing knob. Insert gunend through open

OM-1315 Page 82-8. Installing Drive Roll And Wire Inlet GuideST-150 227-CTools Needed:132451 Securing Screw2 Inlet Wire GuideLoosen screw. Slide tip a

OM-1315 Page 92-11. Electrical Service GuideInput Voltage200 220 230 380 415 460 575Input Amperes At Rated Output50 45 44 26 24 22 17Max Recommended S

OM-1315 Page 102-13. Threading Welding Wire1 Wire Spool2 Welding Wire3 Inlet Wire Guide4 Pressure Adjustment Knob5 Drive Roll6 Outlet Wire Guide7 Gun

OM-1315 Page 11SECTION 3 – OPERATION3-1. ControlsRef. ST-147 589-A / Ref. ST-174 835-A1 Parameter Increase Button2 Parameter Decrease Button3 Paramete

OM-1315 Page 12SECTION 4 – PROGRAMMING THE MICROPROCESSORExperiment with the microprocessor. If you have difficulties, reset the unitaccording to Sect

OM-1315 Page 134-2. Parameter Select ButtonRef. ST-147 589-A1 Parameter Display2 Moving LineMoving line is under value that canbe changed.3 Parameter

OM-1315 Page 144-4. Weld ModeMa t e r i a l>We l dTimerDua l Schd>Me m o r y O f f122 IPM17.5 Vo l t12341 Weld ModeSelect Weld to set wire speed

OM-1315 Page 154-6. Dual Schedule Mode And Gun SwitchesMa t e r i a lWe l dTimer>D u a l S c h dSw i t ch A>Me m o r y 1Sw i t ch BMemo r y 212(

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

OM-1315 Page 164-8. Setting Language, Wire Speed Units, And Burnback1 Mode And Parameter SelectButtons2 Power SwitchPress and hold down both buttonswh

OM-1315 Page 174-9. Using One Switch To Control Voltage And Wire Speed (Synergic Welding)Ma t e r i a l>We l dTimerDua l SchdSet up weld program.Se

OM-1315 Page 18SECTION 5 – MAINTENANCE AND TROUBLESHOOTING5-1. Routine MaintenanceY Disconnect power before maintaining.3 MonthsReplace unreadablelabe

OM-1315 Page 195-4. Replacing Gun Contact TipST-149 326-BY Turn Off power.1 Nozzle2 Contact TipCut off welding wire at contact tip.Remove nozzle.Remov

OM-1315 Page 205-7. Cleaning Or Replacing Gun LinerRef. ST-800 797-ATools Needed:3/8 inTo Reassemble Gun:Insert new liner.Install and tighten wire out

OM-1315 Page 215-8. Replacing Switch And/Or Head TubeRef. ST-800 795-ATools Needed:Do not disturb cable connection betweencable connector and connecto

OM-1315 Page 225-9. TroubleshootingTrouble RemedyNo weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-12).Replace b

OM-1315 Page 235-10. Selftest Procedure1 Mode And Parameter SelectButtons2 Power SwitchPress and hold down both buttonswhile turning On unit.3 Switch

OM-1315 Page 245-11. Troubleshooting DisplaysTrouble RemedyRelease Trigger displayed. Release gun trigger.Check gun trigger and leads.There is high fr

OM-1315 Page 25SECTION 6 – ELECTRICAL DIAGRAMSC-168 541-AFigure 6-1. Circuit Diagram

The following terms areused interchangeablythroughout this manual:MIG = GMAWTABLE OF CONTENTSSECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . .

OM-1315 Page 26SECTION 7 – PARTS LISTST-148 324-E1234Fig 7-25678910Fig 7-511121314151617197820212223Fig 7-32418Fig 7-625. Hardware is common andnot av

OM-1315 Page 27DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-1. Main AssemblyQuantity1 148 597 COUPLER, rod threaded .312-18 x 1.000 1. . . . . . . . .

OM-1315 Page 28123456789761112 13141516181920212217232425262728303135Fig 7-4343332ST-148 325-C1029. Hardware is common andnot available unless listed.

OM-1315 Page 29DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-2. Baffle, Center w/Components (Fig 7-1 Item 4)Quantity1 058 427 RING, retaining spool 1. .

OM-1315 Page 30QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-3. Panel, Front w/Components (Fig 7-1 Item24)1 147 582 LENS, clear anti-glare .030 x

OM-1315 Page 31DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-4. Wire Drive And Gears (Fig 7-2 Item 35)Quantity1 602 009 SCREW, .250-20 x 1.25 soc hd gr 8

OM-1315 Page 32Table 7-1.Drive Roll And Wire Guide KitsNoteBase selection of drive rolls upon the following recommended usages:1 V-Grooved rolls for h

OM-1315 Page 33QuantityDescriptionPartNo.ItemNo.Figure 7-6. M-25M Gun (Fig 7-1 Item 25)1 ♦169 724 NOZZLE, slip type .500 orf .125 recess 1. . . . . .

OM-1315 Page 34QuantityDescriptionPartNo.ItemNo.Figure 7-6. M-25M Gun (Fig 7-1 Item 25) (Continued)13 172 018 M25 UNICABLE CLAMP KIT, (consisting of)

Notes

Notes

Notes

1/95OPTIONS AND ACCESSORIESM40AL GUN(#169 608)For welding with aluminum wire.Rated 525 amps at 60% dutycycle or 275 amps at 100% dutycycle using argo

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 7/00Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-1315 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_5/971-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith

OM-1315 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Spark

OM-1315 Page 31-3. Additional Symbols for Installation, Operation, and MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or

OM-1315 Page 41-5. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flow

OM-1315 Page 5SECTION 2 – INSTALLATION2-1. SpecificationsMax. Open-Amps Input at Rated Output, 50 or 60 Hz, Single-PhaseRated OutputCircuitVoltage200