Instruction/ maintenance manual of the product 255 Miller Electric
Go to page of 40
Auto Arc 255 And M-25 Gun Processes Description R MIG (GMA W) W elding Flux Cored (FCA W) W elding Arc Welding Power Source And Wire Feeder OM-157 066V November 2000 For W arranty Claims And T echnical Support, Contact: Milweld Inc., National Distributor P .
.
The following terms are used interchangeably throughout this manual: MIG = GMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . .
.
OM-157 066 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message.
OM-157 066 Page 2 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. ARC RA YS can burn eyes and skin. 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.
OM-157 066 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 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.
OM-157 066 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields.
OM-157 066 Page 5 SECTION 2 – INST ALLA TION 2-1. Specifications Rated W elding Amperage Range Maximum Open- Amperes Input at Rated Load Output, 50 or 60 Hz, Single-Phase Output DC Circuit V oltage DC 200 V 230 V 460 V 575 V KV A KW 200 A @ 28 V o lts DC, 60% Duty Cycle 250 A @ 28 V olts DC, 40% Duty Cycle 40 – 250 42 46 1.
OM-157 066 Page 6 6 Minutes W elding 4 Minutes Resting 2-3. W elding Power Source Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs.
OM-157 066 Page 7 2-5. Installing Work Clamp 1 W ork Cable 2 Boot Slide boot onto work cable. Route cable out front panel opening from inside. 3 Negative ( – ) Output T erminal Connect cable to terminal and cover connection with boot. 4 Hardware 5 W ork Clamp Route cable through clamp handle and secure as shown.
OM-157 066 Page 8 2-7. Installing Welding Gun Ref. ST-800 921-C 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gun en d through opening until it bottoms against drive assembly . T ighten nut. 4 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar .
OM-157 066 Page 9 2-9. Setting Gun Polarity 1 Polarity Changeover Label Always read and follow manufac- ture ’ s recommended polarity . 3/4, 1 1/16 in T ools Needed: 1 Ref. 190 821-A 2-10. Positioning Jumper Links Ref. ST-800 922-C Check input voltage available at site.
OM-157 066 Page 10 2-1 1. Electrical Service Guide Input V oltage 200 230 460 575 Input Amperes At Rated Output 46 40 20 16 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit B.
OM-157 066 Page 1 1 2-13. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight. 4 7 1 Ref. ST-148 261-D / ST -159 218-C / ST-801 083 / S-0627-A 6 in (150 mm) 4 in (102 mm) WOOD Open pressure assembly .
OM-157 066 Page 12 SECTION 3 – OPERA TION 3-1. Front Panel Controls Ref. ST-171 639-C / Ref. ST -174 843-A Controls For Standard Units 1 Wire Speed Control The scale around the control is percent, not wire feed speed. 2 V oltage Switch Use control and V oltage Range Selector (see Section 3-2) to set arc voltage.
OM-157 066 Page 13 3-2. Center Baffle Controls Ref. ST-800 919-B / S-171 601 1 Wire Mode Switch Fo r better control of wire speed use th e Low position when wire speed is between 90 and 670 ipm. Use the Full position when wire speed is between 150 ipm and 1030 ipm.
OM-157 066 Page 14 3-3. W eld Parameter Chart.
OM-157 066 Page 15 Ref. 200 062.
OM-157 066 Page 16 SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions.
OM-157 066 Page 17 4-3. Fuses F1 And F2 Ref. ST-800 928-B Y T ur n Off unit, and disconnect input power . 1 Fuse F1 (See Parts List For Rating) F1 protects the 1 15 volts ac winding of transformer T1. If F1 opens, all weld output stops and pilot light PL1 goes out.
OM-157 066 Page 18 4-6. Cleaning Or Replacing Gun Liner Ref. ST-800 797-C 3/8 i n T o Reassemble Gun: Insert new liner . Install and tighten wire outlet guide. Cut liner off 3/4 in (20 mm) (3/8 in [9.5 mm] for aluminum) from head tube. Install adapter , contact tip, and nozzle.
OM-157 066 Page 19 4-7. Replacing Switch And/Or Head T ube Ref. ST-800 795-C 1 Remove handle locking nut. 2 Remove switch housing. Note : If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut.
OM-157 066 Page 20 4-8. T roubleshooting W elding T rouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 2-12). Reset circuit breaker CB1 (see Section 4-2). Replace fuse F1 and/or F2 (see Section 4-3). Replace building line fuse or reset circuit breaker if open (see Section 2-12).
OM-157 066 Page 21 SECTION 5 – ELECTRICAL DIAGRAM SB-173 544-E Figure 5-1. Circuit Diagram For Welding Power Source.
OM-157 066 Page 22 Notes.
OM-157 066 Page 23 SECTION 6 – P ARTS LIST 1 Figure 6-2 – 2 3 5 6 8 9 10 11 12 13 14 16 15 17 18 Figure 6-6 - 20 ST-800 930-D . Hardware is common and not available unless listed. Figure 6-4 – 7 Figure 6-5 – 19 Figure 6-1. Main Assembly Description Part No.
OM-157 066 Page 24 Description Part No. Dia. Mkgs. Item No. Figure 6-1. Main Assembly Quantity 8 146 165 P ANEL, side LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-157 066 Page 25 ST-800 931-D . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 17 20 21 22 23 25 26 27 28 (Fig.
OM-157 066 Page 26 Description Part No. Dia. Mkgs. Item No. Figure 6-2. Baffle, Center w/Components (Fig 6-1 Item 2) Quantity 1 058 427 RING, retaining spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-157 066 Page 27 See T able 6-1 Drive Roll & Wire Guide Kits. 148 529-H . Hardware is common and not available unless listed. Figure 6-3. Wire Drive And Gears T able 6-1. Drive Roll And Wire Guide Kits IMPORT ANT : Base selection of drive rolls upon the following recommended usages: 1.
OM-157 066 Page 28 Description Dia. Mkgs. Item No. Figure 6-3. Wire Drive And Gears (Fig 6-2 Item 28) Quantity Part No. 1 602 009 SCREW, .250-20 x 1.25 soc hd gr 8 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-157 066 Page 29 ST-802 288 . Hardware is common and not available unless listed. 1 2 3 6 7 8 9 10 11 12 13 14 15 16 17 18 5 4 Figure 6-4. Panel, Rear w/Components Description Dia. Mkgs. Item No. Figure 6-4. Panel, Rear w/Components (Fig 6-1 Item 7) Quantity Part No.
OM-157 066 Page 30 ST-802 287 . Hardware is common and not available unless listed. 1 2 4 5 6 7 8 9 10 11 12 13 14 15 3 Figure 6-5. Panel, Front w/Components Description Part No. Dia. Mkgs. Item No. Figure 6-5. Panel, Front w/Components (Fig 6-1 Item 19) Quantity 1 148 956 HANDLE, switch 1 .
OM-157 066 Page 31 Ref. 800 792-B 1 234 56 7 8 9 10 14 17 11 12 11 12 13 9 15 16 Figure 6-6. Exploded View Of Gun.
OM-157 066 Page 32 Quantity Description Part No. Item No. Figure 6-6. Exploded View Of Gun (Fig 1 Item 20) 1 200 258 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes.
Notes.
Effective January 1, 2000 (Equipment with a serial number preface of “ LA ” or newer) This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied.
PRINTED IN USA 1/00 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Please complete and retain with your personal records. Always provide Model Name and Serial/Style Number.
An important point after buying a device Miller Electric 255 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric 255 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric 255 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric 255 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric 255 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric 255, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric 255.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric 255. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric 255 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
