Miller Millermatic 251 Manuel utilisateur

Processes

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Arc Welding Power Source

and Wire Feeder

TM-1326B 2006−10

Eff. w/Serial Number LB170597

Millermatic 251

Visit our website at

www.MillerWelds.com File: MIG (GMAW)

TABLE OF CONTENTS

SECTION 1 −SAFETY PRECAUTIONS FOR SERVICING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Servicing Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. California Proposition 65 Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 −DEFINITIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Symbols And Definitions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 −INSTALLATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Welding Power Source Duty Cycle And Overheating 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Volt-Ampere Curves 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Connecting To Weld Output Terminals 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Installing Work Cable And Clamp 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Connecting Spoolmatic) 15A Or 30A Gun 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Setting Gun Polarity For Wire Type 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Installing Gas Supply 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Installing Wire Spool And Adjusting Hub Tension 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Positioning Jumper Links 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Electrical Service Guide 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12. Selecting A Location And Connecting Input Power 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13. Threading Welding Wire 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14. Using Gun/Cable Holder 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-15. Weld Parameters 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 −OPERATION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Voltmeter And Wire Feed Speed Meter Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 −THEORY OF OPERATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 −TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Troubleshooting Table 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Troubleshooting Circuit Diagram For Welding Power Source 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Waveforms For Section 6-2 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Main Control Board PC1 Testing Information (Use With Section 6-5) 28. . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Main Control Board PC1 Test Point Values 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Pre-Operational Check 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 −MAINTENANCE 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Unit Overload 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Changing Drive Roll and Wire Inlet Guide 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Aligning Drive Rolls and Wire Guide 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Removing Knob From Front Panel 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 −ELECTRICAL DIAGRAMS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 −PARTS LIST 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-1326 Page 1Millermatic 251

SECTION 1 −SAFETY PRECAUTIONS FOR SERVICING

YWarning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

OM-___ - Date, safety_stm 3/06

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

YMarks a special safety message.

.Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Servicing Hazards

YThe symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see

the symbol, watch out, and follow the related instructions to

avoid the hazard.

YOnly qualified persons should service, test, maintain, and re-

pair this unit.

YDuring servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

DDo not touch live electrical parts.

DTurn Off welding power source and wire feeder

and disconnect and lockout input power using

line disconnect switch, circuit breakers, or by removing plug from re-

ceptacle, or stop engine before servicing unless the procedure spe-

cifically requires an energized unit.

DInsulate yourself from ground by standing or working on dry insulat-

ing mats big enough to prevent contact with the ground.

DDo not leave live unit unattended.

DIf this procedure requires an energized unit, have only personnel

familiar with and following standard safety practices do the job.

DWhen testing a live unit, use the one-hand method. Do not put both

hands inside unit. Keep one hand free.

DDisconnect input power conductors from deenergized supply line

BEFORE moving a welding power source.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

DTurn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Troubleshooting Section be-

fore touching any parts.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling

boards or parts.

DUse proper static-proof bags and boxes to

store, move, or ship PC boards.

FIRE OR EXPLOSION hazard.

DDo not place unit on, over, or near combustible

surfaces.

DDo not service unit near flammables.

FLYING METAL or DIRT can injure eyes.

DWear safety glasses with side shields or face

shield during servicing.

DBe careful not to short metal tools, parts, or

wires together during testing and servicing.

HOT PARTS can cause severe burns.

DDo not touch hot parts bare handed.

DAllow cooling period before working on

equipment.

DTo handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

EXPLODING PARTS can cause injury.

DFailed parts can explode or cause other parts to

explode when power is applied to inverters.

DAlways wear a face shield and long sleeves

when servicing inverters.

SHOCK HAZARD from testing.

DTurn Off welding power source and wire feeder

or stop engine before making or changing me-

ter lead connections.

DUse at least one meter lead that has a self-

retaining spring clip such as an alligator clip.

DRead instructions for test equipment.

FALLING UNIT can cause injury.

DUse lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

DUse equipment of adequate capacity to lift and

support unit.

DIf using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

TM-1326 Page 2 Millermatic 251

MOVING PARTS can cause injury.

DKeep away from moving parts such as fans.

DKeep away from pinch points such as drive

rolls.

DHave only qualified persons remove doors,

panels, covers, or guards for maintenance as

necessary.

DKeep hands, hair, loose clothing, and tools

away from moving parts.

DReinstall doors, panels, covers, or guards

when maintenance is finished and before re-

connecting input power.

MAGNETIC FIELDS can affect pacemakers.

DPacemaker wearers keep away from servicing

areas until consulting your doctor.

OVERUSE can cause OVERHEATING.

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before

starting to weld again.

DDo not block or filter airflow to unit.

H.F. RADIATION can cause interference.

DHigh-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communicationsequipment.

DHave only qualified persons familiar with

electronic equipment install, test, and service

H.F. producing units.

DThe user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

DIf notified by the FCC about interference, stop using the

equipmentat once.

DHave the installation regularly checked and maintained.

DKeep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

READ INSTRUCTIONS.

DUse Testing Booklet (Part No. 150 853) when

servicing this unit.

DConsult the Owner’s Manual for welding safety

precautions.

DUse only genuine replacement parts from the

manufacturer.

1-3. California Proposition 65 Warnings

YWelding or cutting equipment produces fumes or gases which

contain chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California Health &

Safety Code Section 25249.5 et seq.)

YBattery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductiveharm. Wash hands after handling.

For Gasoline Engines:

YEngine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive

harm.

For Diesel Engines:

YDiesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

1-4. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Pacemakers:

Pacemaker wearers consult your doctor before welding or going near

welding operations. If cleared by your doctor, then following the above

procedures is recommended.

TM-1326 Page 3Millermatic 251

SECTION 2 −DEFINITIONS

2-1. Symbols And Definitions

Wire Feed Output XDuty Cycle Do Not Switch

While Welding

VVolts Increase On Off

Gas Metal Arc

Welding (GMAW)

Gun

Wire Feed Spool

Gun Gas Input Gas Output

Voltage Input Press To Reset U0Rated No-Load

Voltage (Average)

SECTION 3 −INSTALLATION

3-1. Specifications

Rated Output

Max. Open

Circuit

Amps Input at Rated Output (60% Duty Cycle), 50 or 60 Hz, Single-Phase

d O

Circuit

Voltage 200 (208) V 230 V 400 V 460 V 575 V KVA KW

250 A at 28 VDC,

40% Duty Cycle 200 A at 28 VDC,

60% Duty Cycle 38 48

2.3* 42

2* 24

1.2* 21

1* 17

0.8* 9.8

0.46* 7.5

0.13*

Wire Type and Diameter Wire Feed Speed Dimensions Net Weight

Solid Steel Stainless Steel Flux Cored 25−700 IPM

(65 17 8 m/min)

H: 32 in (813 mm)

W: 19 in (483 mm)

215 lb

(98 kg)

.023 −.045 in

(0.6 −1.2 mm) .023 −.045 in

(0.6 −1.2 mm) .030 −.045 in

(0.8 −1.2 mm)

(.65−17.8 m/min) W: 19 in (483 mm)

D: 39 in (991 mm) (98 kg)

* While idling

Operating Temperature Range −−20C to +40C Storage Temperature Range −-30C to + 50C

TM-1326 Page 4 Millermatic 251

3-2. Welding 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, Thermistor (T)

opens, output stops, and cooling

fan runs. Wait fifteen minutes for

unit to cool. Reduce amperage or

voltage, or duty cycle before

welding.

YExceeding duty cycle can

damage unit and void

warranty.

Overheating

4 Minutes Welding 6 Minutes Resting

6 Minutes Welding 4 Minutes Resting

A or V

Reduce Duty Cycle

Minutes

duty1 4/95 −150 215-A

40% Duty Cycle At 250 Amperes

60% Duty Cycle At 200 Amperes

10 20 30 40 50 60 70 80 90 100

100

150

200

250

300

350

400

450

500

% DUTY CYCLE

WELD AMPERES

3-3. Volt-Ampere Curves

ssb1.1 10/91 −196 844 / S-0700

1 Normal Volt-Ampere Curves

The volt-ampere curves show the

normal minimum and maximum

voltage and amperage output

capabilities of the welding power

source. Curves of other settings fall

between the curves shown.

0 100 200 300 400

AMPERES

VOLTS

TM-1326 Page 5Millermatic 251

3-4. Connecting To Weld Output Terminals

803 778-A

YTurn off power before connecting to

weld output terminals.

YFailure to properly connect weld

cables may cause excessive heat

and start a fire, or damage your ma-

chine.

1 Weld Output Terminal

2 Supplied Weld Output Terminal Nut

3 Weld Cable Terminal

4 Copper Bar

Remove supplied nut from weld output ter-

minal. Slide weld cable terminal onto weld

output terminal and secure with nut so that

weld cable terminal is tight against copper

bar. Do not place anything between weld

cable terminal and copper bar. Make

sure that the surfaces of the weld cable

terminal and copper bar are clean.

Tools Needed:

3/4 in (19 mm)

Do not place

anything between

Correct Installation Incorrect Installation

weld cable terminal

and copper bar.

3-5. Installing Work Cable And Clamp

Ref. 802 474-E

Tools Needed:

3/4 in

1 Work Cable

2 Boot

Route cable through front panel

opening. Slide boot onto work

cable.

3 Negative (−) Output Terminal

Connect cable to terminal and

cover connection with boot.

Close door.

TM-1326 Page 6 Millermatic 251

3-6. Connecting Spoolmatic)15A Or 30A Gun

804 455-A

1 Gun Trigger Plug

Insert plug into receptacle, and

tighten threaded collar.

2 Weld Cable

3 Shielding Gas Hose

Route weld cable through opening

in front panel.

Route gas hose along side panel.

4 Positive Weld Output Terminal

Connect weld cable to weld output

terminal.

5 Regulator/Flowmeter

6 Y-Adapter Fitting

Route shielding gas hose up to

regulator/flowmeter. Connect gas

hose to Y-adapter fitting on regula-

tor/flowmeter.

.Two welding guns may be

connected to the welding

power source at the same time,

but only one welding gun may

be in use at any one time. If the

triggers of both welding guns

are pulled at the same time, the

weld output and wirefeed motor

are disabled.

Tools Needed:

3/4, 5/8 in

TM-1326 Page 7Millermatic 251

3-7. Setting Gun Polarity For Wire Type

1 Polarity Changeover Label

Information

Always read and follow manufacture’s

recommendedpolarity.

3/4, 11/16 in

Ref. 190 821-A

Changing Polarity

Wire Drive

Assembly Lead Work Clamp Lead

+Positive Terminal

Shown as shipped −Electrode Positive (DCEP): For

solid steel, stainless steel, aluminum, or flux core with

gas wires (GMAW).

-Negative Terminal

Electrode Negative (DCEN): Reverse lead connections

at terminals from that shown above for gasless flux core

wires (FCAW). Drive assembly becomes negative.

3-8. Installing Gas Supply

802 028-A / Ref. 802 477-B

Tools Needed:

Obtain gas cylinder and chain to

running gear, wall, or other

stationary support so cylinder

cannot fall and break off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side of

valve, and open valve slightly. Gas

flow blows dust and dirt from valve.

Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install so face is vertical.

5 Regulator/Flowmeter Gas

Hose Connection

6 Welding Power Source Gas

Hose Connection

Connect customer supplied gas

hose between regulator/flowmeter

gas hose connection, and fitting on

rear of welding power source.

7 Flow Adjust

Typical flow rate is 20 cfh (cubic

feet per hour). Check wire

manufacturer’s recommended

flow rate.

1-1/8, 5/8 in

Argon Gas Or

Mixed Gas

.DO NOT use Argon/Mixed gas regulator/flowmeter

with CO2shielding gas. See Parts List for optional

CO2gas regulator/flowmeter.

Rear Panel

TM-1326 Page 8 Millermatic 251

3-9. Installing Wire Spool And Adjusting Hub Tension

When a slight force is needed

to turn spool, tension is set.

15/16 in

Use compression spring

with 8 in (200 mm) spools.

Tools Needed:

072573-B / 802 922

Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wire

spool, follow the procedure as

shown in the illustration.

Remove these

components

from spindle.

Spindle

Spindle Install these

components

onto spindle.

Order extra spring

Part No. 186 437

3-10. Positioning Jumper Links

Ref. 802 476-D

Check input voltage available at

site.

1 Jumper Links Access Door

Open door.

2 Jumper Link Label

Check label −only one is on unit.

3 Input Voltage Jumper Links

Move jumper links to match input

voltage.

Close and secure access door.

Tools Needed:

3/8 in

200VOLTS 230VOLTS

153 980-C

230VOLTS 460VOLTS 575VOLTS

144 916-D

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