Miller Millermatic 250X User manual

Miller Millermatic 250X User manual
Millermatic 251
Issued Aug. 2004 • Index No. DC/12.49
®
Quick
Specs
Industrial Applications
Processes
Metal Fabrication
Maintenance and Repair
Farm
Light Industrial
MIG (GMAW)
Flux Cored (FCAW)
MIG Arc Welding
Power Source
Rated Output
Max. Open-Circuit Voltage 38
Amperage Range 30 – 300 A
Wire Feed Speed 25 – 700 IPM (.064 – 17.8 m/min)
Weight 215 lb (98 kg)
The Power of Blue .
®
Comes Complete With:
Power cord and plug (200/230 V model only)
12 ft (3.7 m), 250 amp M-25 MIG gun for
.030/.035 in wire
Work cable and clamp
Argon mix regulator/flow gauge and hose
Extra contact tips
Factory-installed running gear/cylinder rack
.030/.035 in reversible drive rolls
Set-up and operation video
Consumable compartment and
access to wire drive system
located under side door.
Exclusive internal timers:
● Tip Saver — Weld output shuts off if tip is
shorted to work surface.
● Safety shut-off — Weld output will shut off if no
arc is detected within 3 seconds after gun
trigger is depressed.
● Jog mode — When loading a new roll of wire or
if the gun trigger is accidentally pressed, gas will
shut off after 1 minute and wire will shut off
after 2 minutes saving wire and gas.
Welds materials from 22 gauge up
to 1/2 in thick in a single pass.
NEW! Miller’s patent-pending
Active Arc Stabilizer™ provides
excellent starts proven
superior to the competition!
Line voltage compensation
for constant output with
fluctuations in input power.
Industrial, dual-gear-driven, cast aluminum
drive system features no-tool, quick-change
reversible drive rolls and an easy-to-set,
scaled tension knob.
NEW! Adjustable run-in control
can be individually set for both
MIG and spool guns. Controlled
on the front panel, this easily
accessible feature allows the user
to optimize starts to the application.
Add the optional Spoolmatic® 15A or
30A spool gun for aluminum welding.
No extra module to buy or install.
And with Miller’s exclusive Gun-OnDemand™, simply pull the trigger for
either gun and you’re ready to weld.
No wasted time installing modules
and using toggle switches.
200 Amps at 28 VDC, 60% Duty Cycle
250 Amps at 28 VDC, 40% Duty Cycle
Fan-On-Demand™ only
operates when needed
reducing power
consumption and the
amount of airborne
contaminants pulled
through the machine.
Self-calibrating digital meters allow presetting
of voltage and wire speed, and display actual
settings for 5 seconds after you stop welding.
With spool gun, wire speed meter displays actual
WFS setting — a feature not available on
competitive units. Meters also display help
messages for troubleshooting purposes.
Welder/generator is warranted for 3 years, parts and labor.
Original main power rectified parts are warranted for 5 years.
Gun warranted for 90 days, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
(Subject to change without notice.)
Max. OpenRated Output
Circuit Voltage
200 A at 28 VDC, 38
60% Duty Cycle
Amps Input at Rated Output, 60 Hz
200 V 230 V 400 V 460 V 575 V KVA KW
48
42
23
21
17
10 7.7
Wire Type and Diameter
Solid Steel: .023–.045 in (0.6–1.2 mm)
Stainless Steel: .023–.035 in (0.6–0.9 mm)
Flux Cored: .030–.045 in (0.8–1.2 mm)
250 A at 28 VDC,
40% Duty Cycle
Wire Feed
Speed
25–700 IPM
(0.64–17.8
m/min)
Net
Dimensions Weight
H: 32 in
215 lb
(813 mm) (98 kg)
W:19 in
(483 mm)
D: 39 in
(991 mm)
Certified to both the Canadian and U.S. Standards for welding equipment.
Performance Data
Control Panel
DUTY CYCLE CHART
1
4
®
251
WELD AMPS
1. Voltmeter
2. Wire Speed Meter
3. MIG Gun Connection
4. Voltage Control
5. Wire Speed Control
6. Power Switch
7. Spool Gun Connection
500
450
400
350
300
250
200
150
100
5
2
50
10
20
30
40
50
60 70 80 90 100
% DUTY CYCLE
VOLT/AMP CURVES
35
6
30
OFF
VOLTS
25
7
3
20
15
10
5
0
0
100
200
300
400
AMPERES
Options (Order Push-Pull Module, Gun, and Drive Roll and Accessory Kit separately.)
Millermatic 251 Push-Pull Module
XR-A Edge Gun
Able to utilize 12 in rolls
of aluminum wire inside the
Millermatic 251 for extended
aluminum welding time.
U-Groove Aluminum Drive Roll
and Accessory Kits
Wire feed speed is adjustable at the gun and
actual speed can be seen on the digital display on
the Millermatic 251.
Note: XR-Edge/Pistol kits include U-groove machine
drive rolls, nylon wire guides, gun drive rolls and
contact tips. XR-A Python kits include U-groove
machine drive rolls, nylon wire guides and contact tips.
Adjustable run-in control to fine tune arc starting.
XR-A Pistol Gun
XR-A Python® Gun
Add the optional Push-Pull Module for
aluminum wire feed capability. XR™-Edge,
XR-A Pistol or XR-A Python guns can be
directly connected to the Millermatic 251
with this module.
True push-pull design where the Millermatic
drive system provides constant torque to the wire
and the gun provides constant wire feed speed.
2
NEW! XR-A Python Gun 25 ft #195 373
Performs well on thin aluminum.
Push-Pull Module #195 324
For use with Millermatic 251 units, effective
with serial #LE152159. For Millermatic 251
units prior to #LE152159, contact the Miller
Electric Service Dept.
XR-A Edge Gun
#181 534 15 ft (4.6 m) Cable
#181 535 30 ft (9 m) Cable
XR-A Pistol Gun
#198 127 15 ft (4.6 m) Cable
#198 128 30 ft (9 m) Cable
For XR-A Edge
#195 199 .035 in (0.9 mm)
#195 274 .040 in (1 mm)
#195 200 .047 in (1.2 mm)
For XR-A Pistol
#195 201 .035 in (0.9 mm)
#195 273 .040 in (1 mm)
#195 202 .047 in (1.2 mm)
For XR-A Python
#195 311 .035 in (0.9 mm)
#195 312 .040 in (1 mm)
#195 313 .047 in (1.2 mm)
Genuine Miller Accessories
Millermatic® PSA Adapter #195 019
Adapts Miller 24 VAC wire feeders to
the Millermatic 251. Call factory for
specific applications.
M-25 Replacement Gun
#169 594 10 ft (3 m)
#169 596 12 ft (3.7 m) standard
Gun shipped to run .030 –.035 in
(0.8 – 0.9 mm) wire.
Spoolmatic® 15A Spool Gun #195 156
Spoolmatic® 30A Spool Gun #130 831
Ideal for aluminum welding jobs. 200 amp,
100% duty cycle, air-cooled, 1 lb spool
gun with your choice of 15 ft or (4.6 m)
30 ft (9.1 m) cable assembly. For detailed
information, see Spoolmatic literature,
Index No. M/1.2.
Consumables
Dual Cylinder Rack #042 758
Converts single cylinder rack to a dual rack.
Millermatic® Protective Cover with
Helmet Bag #195 142
CO2 Regulator/Flow Gauge #212 492
Required if using 100% CO2 gas.
Order from Miller Service Parts.
(Order from Miller Service Parts.)
For M-25 Gun
Contact Tips
#087 299 .023/.025 in (0.6 mm)
#000 067 .030 in (0.8 mm)
#000 068 .035 in (0.9 mm)
#000 069 .045 in (1.1 mm)
#187 117 .035 in (0.9 mm) heavy-duty tip
#187 118 .045 in (1.2 mm) heavy-duty tip
Tapered Contact Tips
#176 797 .030 in (0.8 mm)
#176 793 .035 in (0.9 mm)
#176 794 .045 in (1.2 mm)
Contact Tip Adapter #169 728
Replacement Liners
#194 010 .023/.025 in
#194 011 .030 –.035 in (standard)
#194 012 .035 –.045 in
Note: Flush or stickout
nozzles should be used for
the short-circuit process.
Recessed nozzles should be
used for the spray arc process.
Nozzles
#200 258 Standard
1/2 in (13 mm) diameter orifice. Nozzle
flush with contact tip.
#169 726
5/8 in (16 mm) diameter orifice. Nozzle
flush with contact tip.
#169 727
5/8 in (16 mm) diameter orifice. Contact tip
sticks out of nozzle 1/8 in (3.2 mm).
#169 724
1/2 in (13 mm) diameter orifice. Contact tip
recessed 1/8 in (3.2 mm) into nozzle.
#169 725
5/8 in (16 mm) diameter orifice. Contact tip
recessed 1/8 in (3.2 mm) into nozzle.
Spot Nozzles
#176 238 Flat
#176 240 Inside corner
#176 242 Outside corner
Tapered Nozzles
Note: Tapered tips are recommended when using a
tapered nozzle.
Gun Convenience Kit #195 975
Contains:
5 – .035 in (0.9 mm) contact tips
(#000 068)
5 – .045 in (1.2 mm) contact tips
(#000 069)
2 – Tip adapters (#169 728)
1 – Nozzle adapter (#169 729)
3 – O-rings (#170 468)
2 – Shock washers (#169 730)
1 – 5/8 in (16 mm) diameter orifice nozzle
(#169 726)
Drive Rolls
Note: Drive roll kits include two drive rolls and an
inlet guide.
V-Grooved Drive Roll Kits
#204 579 .030/.035 in (0.8/0.9 mm)
reversible
#087 131 .023/.025 in (0.6 mm)
#079 594 .030 in (0.8 mm)
#079 595 .035 in (0.9 mm)
#079 596 .045 in (1.2 mm)
V-Knurled Drive Roll Kits
#079 606 .035 in (0.9 mm)
#079 607 .045 in (1.2 mm)
#176 243 3/8 in (9.5 mm) diameter orifice
#178 386 11/32 in (8.7 mm) diameter orifice
3
Typical Installations
Gun
MIG (GMAW) or Flux Cored (FCAW)
Basic Equipment
Shielding
Gas Cylinder
Work
Ordering Information
Equipment and Options
Stock No.
Description
Millermatic 251
#903 868
#903 869
#951 007
#951 009
200(208)/230 V, 60 Hz
230/460/575 V, 60 Hz
200(208)/230 V, 60 Hz w/ Spoolmatic 30A, dual cylinder rack, regulator and hose
230/460/575 V, 60 Hz w/ Spoolmatic 30A, dual cylinder rack, regulator and hose
#169 594
#169 596
#195 156
#130 831
10 ft (3 m), .030 –.035 in (0.8 – 0.9 mm)
12 ft (3.7 m), .030 –.035 in (0.8 – 0.9 mm)
Spool gun for aluminum
Spool gun for aluminum
#195 324
#181 534
#181 535
#198 127
#198 128
#195 373
#195 199
#195 274
#195 200
#195 201
#195 273
#195 202
#195 311
#195 312
#195 313
For use with Millermatic 251, effective with serial #LE152159
15 ft (4.6 m)
30 ft (9 m)
15 ft (4.6 m)
30 ft (9 m)
25 ft (7.6 m)
For XR-A Edge Gun, .035 in (0.9 mm)
For XR-A Edge Gun, .040 in (1 mm)
For XR-A Edge Gun, .047 in (1.2 mm)
For XR-A Pistol Gun, .035 in (0.9 mm)
For XR-A Pistol Gun, .040 in (1 mm)
For XR-A Pistol Gun, .047 in (1.2 mm)
For XR-A Python Gun, .035 in (0.9 mm)
For XR-A Python Gun, .040 in (1 mm)
For XR-A Python Gun, .047 in (1.2 mm)
#042 758
#195 019
#195 142
#212 492
Field
Adapts any 24 VAC wire feeder to the Millermatic 251
#193 975
Includes tips, nozzle, O-rings, washers, etc for M-25 gun
®
Millermatic® 251 Packages
Guns
M-25 Gun
Spoolmatic® 15A
Spoolmatic® 30A
Push-Pull Module Option
Millermatic 251 Push-Pull Module
XR-A Edge Gun
XR-A Pistol Gun
NEW! XR-A Python Gun
U-Groove Aluminum Drive Roll and Accessory Kit
Accessories
Dual Cylinder Rack
Millermatic PSA Adapter
Protective Cover with Helmet Bag
CO2 Regulator/Flow Gauge
Electrode Wire
Shielding Gas Cylinder
Helmet/Gloves/Scratch Brush
Consumables (Order from Miller Service Parts.)
Contact Tips/Tapered Contact Tips
Contact Tip Adapter
Replacement Liners
Nozzles/Spot Nozzles/Tapered Nozzles
Gun Convenience Kit
Drive Rolls
Date:
Required if using 100% CO2 gas. Order from Miller Service Parts
Total Quoted Price:
Distributed by:
Litho in USA
Qty.
Price
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