Miller Electric 225, 300 manual

AC/DC, 300/200 AC/DC, 225, And 300

Processes

Description

Arc Welding Power Source

OM-316 087 083Q

August 2004

Thunderbolt XL

Stick (SMAW) Welding

225 And 300 Models:

AC/DC, 300/200 AC/DC Models:

Visit our website at

www.MillerWelds.com

Contents

Main Thunderbolt XL AC/DC, 300/200 AC/DC, 225, And 300 From Miller to You TABLE OF CONTENTS Page SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage . 1-2. Arc Welding Hazards ELECTRIC SHOCK can kill. ARC RAYS can burn eyes and skin. WELDING can cause fire or explosion. FLYING METAL can injure eyes. BUILDUP OF GAS can injure or kill. HOT PARTS can cause severe burns. 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING STATIC (ESD) can damage PC boards. 1-5. Principal Safety Standards 1-6. EMF Information OM-316 Page 5 SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 2-1. Signification des symboles . 2-2. Dangers relatifs au soudage larc LES DCHARGES LECTRIQUES peuvent tre mortelles. LES RAYONS DE LARC peuvent cau- ser des brlures oculaires et cuta- nes. LE SOUDAGE peut causer un incen- die ou une explosion. LES PARTICULES PROJETES peu- vent blesser les yeux. LES ACCUMULATIONS DE GAZ peu- vent causer des blessures ou mme la mort. LES PICES CHAUDES peuvent cau- ser des brlures graves. 2-3. Autres symboles relatifs linstallation, au fonctionnement et lentretien de lappareil. 2-4. Principales normes de scurit 2-5. Information sur les champs lectromagntiques SECTION 3 DEFINITIONS A SECTION 4 INSTALLATION 4-1. Specifications AC/DC Models AC Models 4-2. Duty Cycle Charts OM-316 Page 12 4-3. Volt-Ampere Curves A. For AC/DC Models DC Amperes A. For 115/230, 230 And 460 Volt Models (225/150 Amperes) B. For 220, 230/400, And 460 Volt Models (300/200 Amperes) B. For AC Models A. For 115/230 And 230 Volt Models (225 Amperes) B. For 220 Volt Model (300 Amperes) C. For 230/400 Volt Model (300 Amperes) 4-4. Selecting A Location 4-5. Installing Electrode Holder And Work Clamp 4-6. Weld Output Cables For weld output cable replacements or extensions, contact your Factory Authorized Service Agent. 4-7. Electrical Service Guide . Page 4-10. Connecting Input Power 1 Or 1 SECTION 5 OPERATION 5-1. Controls A. Controls For AC/DC Models B. Controls For AC Models SECTION 6 MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance 3 Months 6 Months 12 Months 6-2. Lubricating Shunt Block And Anti-Noise Adjustment 6-3. Reinstalling Amperage Adjustment Indicator 6-4. Troubleshooting Trouble Remedy Page Page Page Page Page SECTION 8 WELDING METHODS & TROUBLESHOOTING A. Welding Methods 8-1. Shielded Metal Arc Welding (SMAW) Procedure 8-2. Electrode And Amperage Selection Chart 400 350 300 250 8-3. Striking An Arc 8-4. Positioning The Electrode Holder 8-5. Weld Bead Characteristics 8-6. Conditions That Affect Weld Bead Shape 8-7. Electrode Movement During Welding . 8-8. Butt Joints 8-9. Lap Joints 8-10. Tee Joints B. Welding Troubleshooting Table 6-1. Porosity Table 6-2. Excessive Spatter Table 6-3. Incomplete Fusion Table 6-4. Lack Of Penetration Table 6-5. Excessive Penetration Table 6-6. Burn-Through Table 6-7. Waviness Of Bead Table 6-8. Distortion Page Page Page Page Page Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Effective January 1, 2004 (Equipment with a serial number preface of LE or newer) Please complete and retain with your personal records. For Service Always provide Model Name and Serial/Style Number. Owners Record