13-2, 13-3, 13-4, 13-5 | Miller Electric 250 guide


SECTION 10 − PARTS LIST			41
10-1. Recommended Spare Parts			41
SECTION 11 − ELECTRICAL DIAGRAMS			42
SECTION 12		− RUN-IN AND WETSTACKING	46
12-1.Run-In And Wetstacking			46
SECTION 13		− PERFORMANCE DATA	47
13-1. Fuel Consumption Curves			47
13-2.	Generator Power Curve		48
13-3.	Duty Cycle		48
13-4.	Stick Mode Volt-Ampere Curves		49
13-5.	MIG Mode Volt-Ampere Curve		50
SECTION 14		− GENERATOR POWER GUIDELINES	51
SECTION 15		− STICK WELDING (SMAW) GUIDELINES	58
COMPLETE PARTS LIST - www.MillerWelds.com

OPTIONS AND ACCESSORIES

WARRANTY

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Miller Electric 250 manual 13-2, 13-3, 13-4, 13-5

Contents

OM-217 455H File Engine DriveVisit our website at 2007−05−21 From Miller to You Table of Contents 13-2 13-313-4 13-5 Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burns Fumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosion Engine Hazards Compressed Air Hazards Welding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injury Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interference Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiques LES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion ’EXPLOSION DE LA Batterie peu LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent pro voquer des blessures ’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peut Proposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicaux − Specifications Symbol DefinitionsWeld, Power, and Engine Specifications − Definitions Dimensions For Units With Optional Running Gear Dimensions, Weights, and Operating AnglesDimensions − Installation Installing Welding GeneratorVehicle frame. Always connect a ground wire Mounting Installing Exhaust Pipe Connecting the Battery+ − Stop engine and let cool Overview And Engine Prestart Checks Engine Left Side Engine Right Side Starting engine for the first timeRun-in period first 100 hours Daily pre-start checks Connecting to Weld Output Terminals Correct InstallationWork Weld Output Terminal Tools Needed Do not place Selecting Weld Cable Sizes Engine Control Switches Place switch in Run position to operate most MIG equipment− Operating the Welding Generator Do not use glow plugs longer than 20 seconds Weld Output Controls Typical Stick Welding Connections And Control Settings Typical Settings For 7018 1/8 ElectrodeStop engine Work Clamp Electrode Holder Typical MIG Welding Connections And Settings Set Weld Process Selector switch to Wire + Dcep positionSet Weld Process Selector switch to Wire + position Set Weld Process Selector switch to Wire − position Dcen Tools Needed 3/4 Work Not Used To Work Left Side View Generator Power Receptacles − Operating Auxiliary EquipmentAt least once a month, run engine at To verify Gfci is working properly Simultaneous Weld And Power Battery Charge Controls − Operating Optional Battery ChargerDetermining Battery Charging Current Battery Charge Cable Connections Battery Charging Procedure Minutes Start Your Professional Welding Career Now − Maintenance and Troubleshooting Routine Maintenance Maintenance Label And Engine Maintenance Activities Stop engine and let cool Oil And Fuel 804 197-A / Ref 803 111-A / 227 Cleaner or with dirty element. Engine Ment is not covered by the warrantyAir cleaner primary element can Damage when determining whether Adjusting Engine Speed Adjusting Fuel Solenoid PositionStop screw is factory-set and should not be adjusted Checking Fuel Solenoid Adjusting Throttle Solenoid Checking Throttle Solenoid16 mm Check for non-binding Adjusting Idle Speed Making Engine Speed AdjustmentsAdjusting Weld/Power Speed Overload Protection Component Panel Stop engineFuse F1 Supplementary Protector CB8 Troubleshooting Tables Generator PowerWelding Trouble Remedy Maintenance Display Action Engine − Parts List Recommended Spare PartsRecommended Spare Parts Current transformer CT1, and throttle solenoid TS1 − Electrical Diagrams Circuit Diagram For Welding Generator 228 719-B OM-217 455 231 607-B − RUN-IN and Wetstacking Run-In And Wetstacking − Performance Data Fuel Consumption CurvesUS Gal./Hr Idle Generator Power Curve Duty CycleVolts AC Amperes At 120 Volts DC Amps CC/AC Stick Mode AC Volts Stick Mode Volt-Ampere CurvesAC Amps MIG Mode Volt-Ampere Curve DC Amps Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated in electrical codes Amperes x Volts = Watts Approximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Power Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting Amperage Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Weld current starts when electrode touches work- piece Stick Welding Procedure− Stick Welding Smaw Guidelines Striking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work Angle Conditions That Affect Weld Bead Shape Electrode Movement During Welding Butt Joints Lap JointTee Joint 16 in 30 1.6 mm Tack Welds Troubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective Actions Troubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Work like a Pro Your distributor also gives ServiceSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s

Miller Electric 250 manual 13-2, 13-3, 13-4, 13-5

Models: 250

TABLE OF CONTENTS

13-2.

13-3.

13-4.

13-5.