OWNER’S MANUAL - MillerWelds

1 owner SMANUALF ebruary 1996 Form: OM-403 CEffective With Serial No. KG045632cover_om 4/95 Ref. ST-800 392-BPRINTED IN USA 1996 MILLER Electric Mfg. 225G (Onan-Powered)CC/CV AC/DC Welding Generator For SMAW, FCAW, GMAW, GTAW WeldingWeldingModeWeldOutputRangeRatedWe ldingOutputMaximumOpen-CircuitVoltageAux iliary PowerRatingFuel CapacityEngineCC/AC50 225 A225 A, 25 V,100% DutyCycle80 Onan Performer P216CC/DC50 210 A210 A, 25 V,100% DutyCycle72 Single-Phase,8 kVA/kW, 70/35 A,120/240 V AC, 60 gal (32 L) TankOnan Performer P216 Air-Cooled, Two-Cylinder,Four-Cycle, 16 HPGasoline EngineCV/DC17 28 V200 A, 20 V,100% DutyCycle33 Gasoline EngineOM-403C 2/96 TABLE OF CONTENTSSECTION 1 SAFETY PRECAUTIONS FOR ARC WELDING1.

2 Usage1.. Welding Hazards1.. Hazards2.. Installation, Operation, And Maintenance Hazards3.. Safety Standards3.. Information3.. SECTION 2 INSTALLATION7.. Welding Generator7.. , Weights, And Operating Angles7.. Consumption8.. Prestart Checks8.. The Battery9.. Output Terminals And Selecting Cable Sizes9.. SECTION 3 OPERATING WELDING GENERATOR9.. Panel Symbols And Definitions9.. Panel Controls10.. Cycle11.. SECTION 4 OPERATING AUXILIARY EQUIPMENT12.. Receptacles12.. Optional 240 Volt Plug13.. SECTION 5 MAINTENANCE AND TROUBLESHOOTING14.

3 Maintenance14.. Label15.. Air Cleaner16.. Engine Oil, Oil Filter, And Fuel Filter17.. Engine Speed18.. Protection19.. And Cleaning Optional Spark Arrestor19.. SECTION 6 ELECTRICAL DIAGRAM22.. SECTION 7 PARTS LIST24.. Figure 7-1. Main Assembly24.. Figure 7-2. Bracket, Mtg w/Components26.. Figure 7-3. Panel, Front w/Components27.. Figure 7-4. Generator28.. OM-403 Page 1 SECTION 1 SAFETY PRECAUTIONS FOR ARC WELDING safety_rom1 4/951-1. Symbol UsageMeans Warning! Watch Out! There are possible hazards with thisprocedure! The possible hazards are shown in the adjoining group of symbols means Warning!

4 Watch Out! possible ELECTRIC SHOCK, MOVING PARTS,and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions toavoid the a special safety NOTE; not safety Arc Welding HazardsWARNINGThe symbols shown below are used throughout this MANUAL to call attention to and identify possible you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safetyinformation given below is only a summary of the more complete safety information found in the SafetyStandards listed in Section 1-5.

5 Read and follow all Safety qualified persons should install, operate, maintain, and repair this operation, keep everybody, especially children, SHOCK can live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic orautomatic wire welding, the wire, wire reel, drive rollhousing, and all metal parts touching the weldingwire are electrically live. Incorrectly installed orimproperly grounded equipment is a Do not touch live electrical Wear dry, hole-free insulating gloves and body Insulate yourself from work and ground using dry insulating matsor covers big enough to prevent any physical contact with thework or Disconnect input power or stop engine before installing orservicing this equipment.

6 Lockout/tagout input power accordingto OSHA 29 CFR (see Safety Standards).5. Properly install and ground this equipment according to itsOwner s MANUAL and national, state, and local Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminalin disconnect box or that cord plug is connected to a properlygrounded receptacle When making input connections, attach proper groundingconductor first double-check Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can Turn off all equipment when not in Do not use worn, damaged, undersized, or poorly spliced Do not drape cables over your If earth grounding of the workpiece is required, ground it directlywith a separate cable do not use work clamp or work Do not touch electrode if you are in contact with the work, ground.

7 Or another electrode from a different Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to Wear a safety harness if working above floor Keep all panels and covers securely in Clamp work cable with good metal-to-metal contact to workpieceor worktable as near the weld as RAYS can burn eyes and skin;NOISE can damage hearing; FLYINGSLAG OR SPARKS can injure rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Noise from someprocesses can damage hearing.

8 Chipping, grinding,and welds cooling throw off pieces of metal or Use approved ear plugs or ear muffs if noise level is RAYS2. Wear a welding helmet fitted with a proper shade of filter to protectyour face and eyes when welding or watching (see ANSI listed in Safety Standards).3. Wear approved safety glasses with side Use protective screens or barriers to protect others from flashand glare; warn others not to watch the Wear protective clothing made from durable, flame-resistantmaterial (wool and leather) and foot AND GASES can be hazardousto your produces fumes and gases.

9 Breathingthese fumes and gases can be hazardous to Keep your head out of the fumes. Do not breathe the If inside, ventilate the area and/or use exhaust at the arc toremove welding fumes and If ventilation is poor, use an approved air-supplied Read the Material Safety Data Sheets (MSDSs) and themanufacturer s instruction for metals, consumables, coatings,cleaners, and Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trainedwatchperson nearby. Welding fumes and gases can displace airand lower the oxygen level causing injury or death.

10 Be sure thebreathing air is Do not weld in locations near degreasing, cleaning, or sprayingoperations. The heat and rays of the arc can react with vapors toform highly toxic and irritating Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from theweld area, the area is well ventilated, and if necessary, whilewearing an air-supplied respirator. The coatings and any metalscontaining these elements can give off toxic fumes if Page 2 CYLINDERS can explode if gas cylinders contain gas under highpressure.