Miller AUTO ARC 255 Owner's manual

AUTO ARC 255
Miller
Brand
Miller
Model
AUTO ARC 255
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller AUTO ARC 255 is a versatile welding power source and wire feeder designed for GMAW and FCAW welding processes. It delivers 200 amps at 28 volts DC with a duty cycle of 60%, making it suitable for various welding applications. The AUTO ARC 255 handles wire diameters ranging from .023 to .045 for hard wire and .030 to .045 for flux-cored wire. It comes equipped with a gun and shielding gas valve, providing a complete welding solution.

Miller AUTO ARC 255 is a versatile welding power source and wire feeder designed for GMAW and FCAW welding processes. It delivers 200 amps at 28 volts DC with a duty cycle of 60%, making it suitable for various welding applications. The AUTO ARC 255 handles wire diameters ranging from .023 to .045 for hard wire and .030 to .045 for flux-cored wire. It comes equipped with a gun and shielding gas valve, providing a complete welding solution.

AUTO
ARCJfi
April
1995
Form:
OM-157
066C
Effective
With
Serial
No.
KF869436
OWNERS
MANUAL
Auto
Arcfi
Model
255
Read
and
follow
these
instructions
and
all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Give
this
manual
to
the
operator.
U
For
help,
call
your
distributor
Call
your
distributor
if
you
do
not
understand
I~J
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
the
directions.
Appleton,
WI
54912
414-734-9821
DC/CV
Welding
Power
Source/Wire
Feeder
For
GMAW
And
FCAW
Welding
Uses
.023
.045
Hard
Wire
And
.030
.045
Flux
Cored
Wire
200
Amperes,
28
Volts
DC
At
60%
Duty
Cycle
Uses
Single-Phase
Input
Power
Overheating
And
Motor
Overload
Protection
Includes
Gun
And
Shielding
Gas
Valve
auto_arc
7/93
ST-i
57
072-A
PRINTED
IN
USA
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1995
(Equipment
with
a
serial
number
preface
of
KO
or
newer)
This
limited
wsrrsnty
supersedes
sit
previous
MILLER
wsrrsnties
snd
is
exclusive
with
no
other
gusrsntees
or
wsrrsnties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
snd
conditions
below,
MILLER
Electric
Mtg.
Co.,
Appleton,
Wisconsin,
wsrrsnts
to
its
originsl
retail
purchsser
thst
new
MILLER
equipment
sold
sher
the
effective
dste
ot
this
limited
warrsnty
is
free
ot
de
tects
in
msterisl
snd
workmanship
st
the
time
it
is
shipped by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
wsrrsnty
periods
listed
below,
MILLER
will
repsir
or
replsce
sny
war
rsnted
psrts
orcomponents
thst
fsil
due
to
such
detects
in
material
or
workmsnship.
MtLLER
must
be
notitied
in
writing
within
thirty
(30)
dsys
ot
such
detect
or
tsilure,
st
which
time
MILLER
will
provide
instructions
on
the
wsrrsnty
clsim
procedures
to
be
followed.
MILLER
shsll
honor
wsrrsnty
clsims
on
wsrrsnted
equipment
listed
below
in
the
event
ot
such
s
tsilure
within
the
wsrrsnty
time
periods.
All
wsrmnty
time
periods
slsrt
on
the
dste
thst
the
equipment
wss
delivered
to
the
original
retsil
purchsser,
or
one
yesr
sher
Ihe
equipment
is
sent
to
s
North
Americsn
distributor
or
eighteen
months
aher
the
equipment
is
sent
to
sn
Internationsl
distributor.
1.
5
Years
Psrts3Yesm
Lsbor
Originst
msin
power
rectitiers
2.
3
Yesrs
Psrts
snd
Lsbor
Trsnsformer/Reclitier
Power
Sources
Ptssms
Arc
Cutting
Power
Sources
*
Semi-Automatic
snd
Automstic
Wire
Feeders
*
Robots
3.
2
Yesrs
Parts
snd
Lsbor
-
Engine
Driven
Welding
Generstors
(NOTE:
Engines
sre
wsrrsnted
sepsrstely
by
the
engine
msnutacturer.)
*
Air
Compressors
4.
1
Yesr
Psrts
snd
Lsbor
-
Motor
Driven
Guns
*
Process
Controllers
IHPS
Power
Sources
*
Wster
Coolsnt
Systems
*
HP
Units
-
Grids
*
Spot
Welders
*
Losd
Bsnks
-
SDX
Trsnsformers
Running
Gesr/Trailers
Plasms
Cutting
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
Tecumseh
Engines
Deutz
Engines
(outside
North
Americs)
*
Field
Options
(NOTE:
Field
options
sre
covered
under
True
BIuaTM
for
the
remsining
wsrrsnty
period
of
the
product
they
sre
instslled
in,
or
for
s
minimum
of
one
yesr
whichever
is
grester.)
5.
6
Months
Bsneries
6.
g~
Dsys
Psrts
snd
Lsbor
MIG
Guns/TIG
Torches
-
APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
Remote
Controls
*
Accessory
Kits
Replscement
Psrts
MILLERS
True
BIueTM
Limited
Warranty
shall
not
apply
to:
1.
Items
furnished
by
MILLER,
but
msnufactured
by
others,
such
ss
engines
or
trsde
sccessories.
These
items
sre
covered
by
the
manufscturers
warrsnty,
if
sny.
2.
Consumable
components:
such
ss
contsct
tips,
cutting
nozzles,
contsctors
end
relays
or
parts
that
fail
due
to
normal
weer.
3.
Equipment
that
hex
been
modified
by
eny
party
other
than
MILLER,
or
equip
ment
that
has
baen
improperly
installed,
Improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CIAL/INDUSTRIAL
USERS
AND PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENT.
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be,
at
MILLERS
option:
(1)
repair:
or
(2)
replacement;
or,
where
authorized
In
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
ol
the
goods
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
Iranaportafion
costs
of
any
kind
will
be
allowed.
TO THE
EXTENT
PERMITtED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
LIABLE
FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEGUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTATION
ASTO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHTARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EOUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
slates
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
Thia
warranty
provides
spe
cific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
slate
to
slate.
In
Canada,
legislation
In
some
provinces
provides
for
certain
additIonal
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
estent
that
they
may
not
be
waived,
the
limitations
and
exclusions
set
out
above
may
not
apply.
This
Limited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
~vary
from
province
to
province.
r.
1–
I
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damagB
with the
delivering
carrier.
Assistance
for
tiling
or
settling
claims
may
be
obtained
from
distributor
and/or
equipmBnt
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
ThB
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of
Purchase
muter
4/95
ARC
WELDING
SAFETY
PRECAUTIONS
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
burns.
The
electrode
and
work
circuit
is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit
and
machine
internal
circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch
live
electrical
parts.
2.
wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
ARC
WELDING
can
be
hazardous.
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
Turn
off
all
equipment
when
not
in
use.
7.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
Do
not
wrap
cables
around
your
body.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
Do
not
touch
electrode
while
in
contact
with
the
work
(ground)
circuit.
11.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
12.
Wear
a
safety
harness
to
prevent
falling
if
working
above
floor
level.
1.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
recommended.
2.
Wear
proper
body
protection
to
protect
skin.
4~
WARNING
PROTECT
YOURSELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL
CONSULTING
YOUR
DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
8.
9.
10.
13.
Keep
all
panels
and
covers
securely
in
place.
L_P
~
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Arc
rays
from
the
welding
process
produce
intense
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
1.
2.
3.
4.
5.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
(see
ANSI
Z49.1
listed
in
Safety
Standards)
to
protect
yourface
and
eyes
when
welding
or
watching.
Wear
approved
safety
glasses.
Side
shields
recommended.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
FUMES
AND
GASES
can
be
hazardous
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
4.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
manufacturers
instruction
for
metals,
consumables,
coatings,
and
cleaners,
wearing
an
air-supplied
respirator.
Shielding
gases
used
for
welding
can
displace
air
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these
elements
can
give
off
toxic
fumes
if
welded.
WELDING
can
cause
tire
or
explosion.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Sparks
and
spatter
fly
off
from
the
welding
arc.
The
flying
sparks
and
hot
metal,
weld
spatter,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
or
welding
wire
to
metal
objects
can
cause
sparks,
overheating,
or
fire.
6.
7.
8.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
Do
not
weld
on
closed
containers
such
as
tanks
or
drums.
Connect
work
cable
to
the
work
as
close
to
the
welding
area
as
practical
to
prevent
welding
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
hazards.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
10.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
If
this
is
not
possible,
tightly
cover
them
with
approved
covers,
contact
tip
when
not
in
use.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
FLYING
SPARKS
AND
HOT
METAL
can
cause
injury.
and
grinding
cause
flying
metal.
As
welds
can
throw
off
slag.
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to treat
them
carefully.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
and
arcs.
2.
Install
and
secure
cylinders
in
an
upright
position
by
chaining
them
to
a
stationary
support
or
equipment
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
5.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
6.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
7.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
8.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
PRINCIPAL
SAFETY
STANDARDS
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
Safefyand
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
American
Weld
ing
Society
Standard
AWS
F4.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Ad,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
A3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protection,
ANSI
Standard
Z87.1,from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
EMF
INFORMATION
TABLE
OF
CONTENTS
SECTION
1
SAFETY
INFORMATION
1
SECTION
2-
SPECIFICATIONS
1
2-1.
Volt-Ampere
Curves
2
2-2.
Duty
Cycle
2
SECTION
3INSTALLATION
3
3-1.
Installing
Work
Clamp
3
3-2.
Installing
Gas
Supply
4
3-3.
Gun
Polarity
Connections
5
3-4.
Installing
Drive
Rolls
And
Welding
Gun
5
3-5.
Connecting
Input
Power
6
3-6.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
. . . .
8
3-7.
Threading
And
Feeding
Welding
Wire
8
SECTION
4-OPERATION
10
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
12
5-1.
Routine
Maintenance
12
5-2.
Overload
Protection
13
5-3.
Wire
Drive
Assembly
Maintenance
14
5-4.
Gun
Maintenance
15
5-5.
Troubleshooting
16
SECTION
6-
ELECTRICAL
DIAGRAMS
16
SECTION
7-
PARTS
LIST
17
Figure
7-1.
Main
Assembly
17
Figure
7-2.
MWG-21C
Gun
18
Figure
7-3.
Baffle
w/Cmpts
19
NOTE
~
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
Background
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
Office,
May
1989):
.
. .
there
is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
cellular
level
and
from
studies
with
animals
and
people
which
clearly
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
or
avoid
potential
risks.
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
the
body.
4.
Keep
welding
power
source
and
cables
as
far
away
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
About
Pacemakers:
The
above
procedures
are
among
those
also
normally
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
modlo
1
4/93
SECTION
1
-
SAFETY
INFORMATION
modl.1
2/93
Read
all
safety
messages
throughout
this
manual.
Obey
all
safety
messages
to
avoid
injury.
Learn
the
meaning
of
WARNING
and
CAUTION.
\4
:1
~
II
~
Figure
1-1.
Safety
Information
SECTION
2-
SPECIFICATIONS
Table
2-1.
Welding
Power
Source
Specifications
-
.
Description
Type
Of
Output
Direct
Current/Constant
Voltage
(DC/CV)
Rated
Weld
Output
200
Amperes,
28
Volts
DC,
60%
Duty
Cycle
(See
Section
2-2)
Type
Of
Input
Power
Single-Phase;
60
Hz;
At
200
Or
230
Volts
AC
Input
Amperes
At
Rated
Output
46
A
At
200
V,
40
A
At
230
V
Maximum
Input
Amperes
While
Idling
1.2
A
At
200
V,
1
A
At
230
V
KVA/KW
Used
At
Rated
Output
9.5
kVAI8.3
kW
Maximum
KVA/KW
Used
While
Idling
0.24
kVAIO.17
kW
Max.
Open-Circuit
Voltage
42
Volts
DC
Control
Circuit
Voltage
At
Gun
24
Volts
DC
Welding
Processes
Gas
Metal
Arc
(GMAW)
And
Flux
Cored
Arc
Welding
(FCAW)
Calculated
Speed
Range
At
No
Load
128
To
.1051
ipm
(3.2
To
266.9
mpm)
Wire Diameter
Range
.030
To
.045
in
(0.8
To
1.1
mm)
Flux
Cored
Wire;
.023
To
.045
in
(0.6
To
1.1
mm)
Hard
Wire
Overall
Dimensions
Length:
37
in
(940
mm);
Width:
19
in
(483
mm);
Height:
30-1/4
in
(768
mm)
Weight
Net:
225
lb
(102
kg);
Ship:
271
lb
(123
kg)
Welding
Gun
Rated
Output
(Air
Cooled)
200
Amperes
At
60%
Duty
Cycle
Using
CO2
Shielding
Gas
(See
Section
2-2)
Cable
Length
15
ft
(4.6
m)
1
2
2
a
CAUTION
/
5
L
~
ELECTRIC
SHOCK
can
kiII~
MOVING
PARTS
can
injure.
Do
not
touch
live
electrical
parts.
~
Keep
away
from
moving
parts.
I
Disconnect
input
power
betoreJJ
4
Keep
all
panels
and
covers
closed
I
installing
or
servicing.
when
operating.
I
1
Safety
Alert
Symbol
2
Signal
Word
WARNING
means
possible
death
or
serious
injury
can
happen.
CAUTION
means
possible
minor
injury
or
equipment
damage
can
happen.
3
Statement
Of
Hazard
And
Result
READ
SAFETY
BLOCKS
at start
of
~
Section
3-1
before
proceeding
~j
NOTE
~
Turn
Off
switch
when
using
high
frequency.
4
Safety
Instructions
To
Avoid
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
Read
safety
blocks
for
each
sym
bol
shown.
7
NOTE
Special
instructions
for
best
oper
ation
not
related
to
safety.
OM-157
066
Page
1
2-1.
Volt-Ampere
Curves
Figure
2-1.
Volt-Ampere
Curves
2-2.
Duty
Cycle
£~
CAUTION
300
250-
Q,
200-
uJ
a.
<
0
~1
w
RATED
O(.IrPUT
-
I----
-
20
30
40 60 00
70
0000
150
Figure
2-2.
Duty
Cycle
Cl)
0
>
0
0
50
40
30
20
10
0
The
volt-ampere
curves
show
the
minimum
and
maximum
voltage
and
amperage
output
capabilities
of
the
welding
power
source.
Curves
of
other
settings
fall
be
tween
the
curves
shown.
ssbl.1
10/91
S8~049424-D
0
25
50
75
100
125
150
175
200
225
DC
AMPERES
WELDING
LO
Do
not
weld
at
r
NGER
THAN
RATED
DUTY
CYCLE
can
damage
unit
or
gun
and
void
warranty.
ated
load
longer
than
shown
below.
wfwarn8.2
8/93
0
Definition
~
Duty
Cycle
is
percentage
of
10
~IE~E~
10
~~minutes
that
unit
or
gun
can
weld
at
rated
load
without
over
Minutes
heating.
UNIT
60%
Duty
Cycle
At
200
Amperes
g
6
Minutes
Welding
4
Minutes
Resting
Chart
GUN
~f=
GUN
%
DUTY
CYCLE
6
minutes
Welding
4
minutes
Resting
sD1.3
8/93
5B-150
215
60%
Duty
Cycle
At
180
Amperes
Using
Mixed
Gas
OM-157
066
Page
2
3-1.
Installing
Work
Clamp
Figure
3-1.
Installing
Work
Clamp
SECTION
3-
INSTALLATION
1
Work
Cable
2
Boot
Slide
boot
onto
work
cable.
Route
cable
out
front
panel
opening
from
inside.
3
Negative
()
Output
Terminal
Connect
cable
to
terminal
and
cov
er
connection
with
boot.
4
Hardware
4
5
Work
Clamp
Route
cable
through
clamp
handle
and
secure
to
top
of
clamp
with
hardware.
Close
door.
Tools
Needed:
r
1/2,
3/4
in
Ref.
51-154
630-A
2
3
OM-157
066
Page
3
3-3.
Gun
Polarity
Connections
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
___________________
swaml.1
2193
Shown
As
Shipped
Set For
Electrode
Positive
(DCEP)
For
Solid
Steel
Or
Aluminum
Wires
(GMAW
Process).
Wire
Drive
Assembly
Lead
To
Positive
(+)
Output
Terminal
Work
Clamp
Lead
To
Negative
()
Output
Terminal
GUN
POLARITY
CHANGEOVER
CONNECTIONS
Reverse
Lead
Connections
For
Electrode
Negative
(DCEN)
For
Flux
Cored
Wires
(FCAW
Process).
Drive
Assembly
Becomes
Negative
1
Polarity
Changeover
Label
2
Wire
Drive
Assembly
3
Positive
(+)
Output
Terminal
4
Negative
()
Output
Terminal
Always
read
and
follow
wire
man
ufacturers
recommended
polarity.
5
Circuit
Breaker
CB1
(see
Section
5-2).
Tools
Needed:
~
3/4,11/l6in
Rot.
ST-153
874-B
S-144
449-c
3
Figure
3-3.
Gun
Polarity
Connections
4
3-4.
Installing
Drive
Rolls
And
Welding
.Gun
5
1
Pressure
Adjustment
2
Pressure
Assembly
3
Drive
Roll
4
Securing
Screw
Install
correct
drive
roll
for
wire
size
and
type
using
supplied
screws.
5
Wire
Drive
Assembly
6
Gun
Securing
Knob
7
Gun
End
Loosen
securing
knob.
Insert
gun
end
through
opening
until
it
bot
toms
against
drive
assembly.
Tighten
knob.
8
Gun
Trigger
Plug
Insert
into
receptacle,
and
tighten
threaded
collar.
Close
pressure
assembly.
Close
door.
ST-
154
621
/
Ret.
ST-154
624-A
7
Tools
Needed:
6
Figure
3-4.
Gun
Connections
OM-157
066
Page
5
3-5.
Connecting
Input
Power
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting
or
Installing.
Have
only
qualified
persons
install
unit.
Installation
must
meet
National
Electrical
Code
and
all
other
codes.
swarn3.1
2/93
A.
Positioning
Jumper
Links
Figure
3-5.
Input
Voltage
Jumper
Links
Location
OM-157
066
Page
6
B.
Connecting
Input
Power
Have
only
qualified
persons
make
this
installation.
1
Line
Disconnect
Device
Of
Proper
Rating
2
230
Volts
AC
Wall
Receptacle
3
Input
Conductors
4
Grounding
Conductor
Select
size
and
length
using
Table
3-1.
Conductor
rating
must
comply
with
national,
state,
and
local
electrical
codes.
Install
and
connect
grounding
conductor
and
input
conductors
in
conduit
or
equivalent
between
wall
receptacle
and
deenergized
line
disconnect
device.
Connect
grounding
conductor
first,
then
line
input
conductors.
Be
sure
grounding
conductor
goes
to
an
earth
ground.
5
Overcurrent
Protection
Select
type
and
size
using
Table
3-1.
Install
into
deenergized
line
disconnect
device
(fused
dis
connect
switch
shown).
6
Input
Power
Plug
Turn
off
unit
Power
switch,
and
connect
plug
to
wall
receptacle.
ssb2.2
12/94
Ret.
ST-154 619-B
I
Ref.
ST-149
405-B
Figure
3-6.
Input
Power
Connections
Table
3-1.
Electrical
Service
Requirements*
Input
Voltage
200 230
input
Amperes
At
Rated
Output
46
40
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes
70
60
Mm
Input
Conductor
Size
In
AWGIKcmiI
8
8
Max
Input
Conductor
Length
In
Feet
(Meters)
89
(27)
117(36)
Mm
Grounding
Conductor
Size
In
AWGIKcmiI
8
10
*
These
values
are
calculated
from
the
1993
edition
of
the
National
Electrical
Code
(NEC).
5-0092-H
Tools
Needed:
OM.157
066
Page
7
3-6.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
Figure
3-7.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
3-7.
Threading
And
Feeding
Welding
Wire
£~
WARNING
CYLINDERS
can
explode
if
damaged.
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
Never
touch
cylinder
with
welding
electrode.
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
welding
or
feeding
wire
using
gun
trigger.
WELDING
WIRE
can
cause
puncture
wounds.
Do
not
press
gun
trigger
until
instructed
to
do
so.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
HOT
SURFACES
can
burn
skin.
Allow
gun
to
cool
before
touching.
swarn5.1
10/91
/swarn2.1
9/91
Turn
Off
unit.
1
Wire
Spool
2
Gun
Contact
Tip
If
necessary,
cut
welding
wire
off
at
contact
tip,
and
retract
wire
onto
spool
and
secure.
3
Retaining
Ring
4
Compression
Spring
Remove
ring
and
pull
off
spool.
Compression
spring
is
used
with
8
in
(200
mm)
spools.
5
Hub
6
Hub
Pin
Slide
spool
onto
hub
so
wire
feeds
off
bottom.
Turn
spool
until
hub
pin
fits
hole
in
back
of
spool.
Reinstall
retaining
ring.
7
Hub
Tension
Nut
Grasp
spool
in
one
hand
and
turn
while
using
a
wrench
to
adjust
hub
tension
nut.
When
a
slight
force
Is
needed
to
turn
spool,
tension
Is
set.
Thread
welding
wire
(see
Section
3-7).
Close
door.
Tools
Needed:
~
15/16
in
Ref.
ST-i
54
626~B
/
Ref.
ST-072
573-B
9
OM-157
066
Page
8
1
Wire
Spool
2
Welding
Wire
3
Inlet
Wire
Guide
4
Pressure
Adjustment
Knob
5
Pressure
Assembly
6
Drive
Roll
7
Outlet
Wire
Guide
8
Gun
Conduit
Cable
Lay
gun
cable
out
straight.
Close
and
tighten
pressure
assembly,
and
let
go
of
wire.
Remove
gun
nozzle
and
contact
tip.
/
Press
gun
trigger
until
wire
comes
out
of
gun.
Reinstall
contact
tip
and
nozzle.
Feed
wire
to
check
drive
roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
/
Cutoff
wire.
Close
and
latch
door.
Figure
3-8.
Threading
And
Feeding
Welding
Wire
ST-800
739-A
I
ST-i
54
251
/
S-0627-A
Hold
wire
tightly
to
keep
it
from
unraveling.
Open
pressure
assembly.
Pull
and
hold
wire;
cut
off
end.
Push
wire
thru
guides
into
gun;
continue
to
hold
wire.
-4
~
I0~~
POWER
~
QOFF
Set
switch.
-4
(
I
-4
OM-157
066
Page
9
SECTION
4-
OPERATION
a
WARNING
ELECTRIC
SHOCK
can
kill.
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
Do
not
touch
live
electrical
parts.
Keep
all
panels
and
covers
securely
in
place
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
area,
or
use
breathing
device.
Read
Material
Safety
Data
Sheets
(MSDSs)
and
manufacturers
instructions
for
material
used.
WELDING
can
cause
tire
or
explosion.
Do
not
weld
near
flammable
material.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
Do
not
weld
on
closed
containers.
Allow
work
and
equipment
to
cool
before
handling
ARCING
can
damage
switch.
Do
not
change
Voltage
switch
position
while
welding.
Arcing
inside
switch
can
damage
contacts,
causing
switch
to
fail.
t1
~
~
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
I
Wear
welding
helmet
with
correct
shade
of
filter.
Wear
correct
eye,
ear,
and
body
protection.
,~
~
~
MOVING
PARTS
can
cause
injury.
S
Keep
away
from
pinch
points
such
as
drive
rolls.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
~
~
MAGNETIC
FIELDS
FROM
HIGH
CUR
RENTS
can
affect
pacemaker
operation.
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
opera
tions.
WELDING
CURRENT
can
damage
elec
tronic
parts
in
vehicles.
Disconnect
both
battery
cables
before
welding
on
a
vehicle.
Place
work
clamp
as
close
to
the
weld
as
possible.
See
Safety
Precautions
at
beginning
of
manual
for
ba
sic
welding
safety
information.
swarn6.2
8/92
Wear
the
following
while
welding:
2
3
/
1
Dry,
Insulating
Gloves
2
Safety
Glasses
With
Side
Shields
3
Welding
Helmet
With
Correct
Shade
Of
Filter
(See
ANSI
Z49.1)
sb3.1
1/94
Figure
4-1.
Safety
Equipment
1
Wire
Mode
Switch
For
better
control
of
wire
speed
use
Low
position
when
wire
speed
is
between
90
and 670
ipm.
Use
Full
position
when
wire
speed
is
be
tween
150
ipm
and
1030
ipm.
2
Voltage
Range
Selector
Place
switch
in
desired
position.
See
inside
rear
cover
for
settings.
Ret.
ST-153
874-B
/
S-171
601
Figure
4-2.
Center
Battle
Controls
OM-157
066
Page
10
Tools
Needed:
1
Wire
Speed
Control
Use
control
to
set
wire
feed
speed.
2
Voltage
Control
Use
control
and
Voltage
Range
Selector
(see
Figure
4-2)
to
set
arc
voltage.
Step
6
of
Low
range
and
Step
1
of
High
range
overlap.
3
Pilot
Light
4
Power
Switch
Use
switch
to
turn
unit
On
and
Off.
The
pilot
light
comes
on
when
unit
is
turned
on.
5
Work
Clamp
Use
wire
brush
or
sandpaper
to
clean
metal
at
weld
joint
area.
Connect
work
clamp
to
clean,
paint-free
location
on
workplece,
as
close
as
possible
to
weld
area,
3
4
Figure
4-3.
Front
Panel
Controls
Ref.
ST-154
622-B
/
ST-171
639/Ref.
ST-154
251
OM-157
066
Page
11
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
LA
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting,
maintaining,
or
servicing.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
maintaining
or
servicing.
Maintenance
and
troubleshooting
to
be
performed
only
by
qualified
persons.
swarns.2
2/93
M
OVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
4~
Keep
away
from
pinch
points
such
as
drive
rolls.
4~
5-1.
Routine
Maintenance
a
Turn
Off
all
power
before
maintaining.
3
Months
Replace
Unreadable
Labels
Clean
_
~
1~ghten
3-1
t~~e)
Terminals
-
14-Pin
Cord
Gas
Hose
Gun
Cable
Figure
5-1.
Maintenance
Schedule
OM-157
066
Page
12
5-2.
Overload
Protection
£~
WARNING
A.
Circuit
Breaker
CB1
B.
Fuses
Fl
And
F2
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
1
Circuit
Breaker
CB1
If
CB1
opens,
wire
feed
stops.
Check
gun
liner
for
blockage
or
kinks,
and
check
for
jammed
wire,
binding
drive
gear,
or
misaligned
drive
rolls.
Allow
a
cooling
period
before
resetting
CB1.
Ref.
ST-153
874-B
Figure
5-2.
Circuit
Breaker
CB1
Turn
Off
unit
and
disconnect
input
power.
1
Fuse
Fl
(See
Parts
List
For
Rating)
Fl
protects
the
115
volts
ac
wind
ing
of
transformer
Ti.
If
Fl
opens,
all
weld
output
stops
and
pilot
light
PL1
goes
out.
2
Fuse
F2
(See
Parts
List
For
Rating)
F2
protects
the
24
volts
ac
winding
of
transformer
Ti.
If
F2
opens,
all
weld
output
stops.
Ref.
ST-800
928-B
C.
Overheating
Figure
5-3.
Fuse
Location
Figure
5-4.
Overheating
OM-157
066
Page
13
5-3.
Wire
Drive
Assembly
Maintenance
4~
WARNING
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
Figure
5-5.
Wire
Drive
Assembly
Maintenance
Turn
Off
unit
and
disconnect
Input
power.
1
Wire
Spool
2
Gun
Contact
Tip
Cut
welding
wire
off
at
contact
tip.
Retract
wire
onto
spool
and
Se-
cure.
3
Drive
Roll
Alignment
Bolt
Turn
in
or
out
until
groove
lines
up
with
wire
guide.
4
Drive
Roll
5
Wire
lnletGuide
Remove
guide
by
pressing
on
barbed
area
or
cutting
off
one
end
near
housing
and
pulling
it
out
of
hole.
Push
new
guide
into
hole
from
rear
until
it
snaps
in
place.
6
Pressure
Roll
Arm
7
Cotter
Pin
8
Pin
9
Screw
10
Bearing
Remove
bearing
as
shown.
Install
new
bearing
and
secure
with
screw.
Reinstall
arm
onto
pin
and
secure
with
cotter
pin.
Thread
welding
wire
(see
Section
3-7).
Close
door.
Tools
Needed:
Ret.
ST-154
626-B
I
SA-145
T6~
I
ST-~54
633
OM-157
066
Page
14
5-4.
Gun
Maintenance
I~hd~~
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
FLYING
METAL
CHIPS
AND
DIRT
can
cause
injury
and
damage
equipment.
Point
gun
away
from
people
and
in
a
safe
direction
when
blowing
out
with
compressed
air.
Figure
5-6.
Gun
Maintenance
swarnlO.1
10191
Turn
Off
unit
and
disconnect
input
power.
1
Wire
Spool
Cut
welding
wire
off
at
contact
tip.
Retract
wire
onto
spool
and
se
cure.
2
Gun
Securing
Knob
Loosen
knob
and
remove
gun
and
trigger
plug.
Reassemble
gun.
To
Reassemble
Gun:
Install
contact
tip.
Insert
new
liner.
Install
collet
onto
liner
and
tighten
into
gun/feeder
connector
using
wrench.
Cut
liner
off
near
collet
so
that
liner
end
is
as
close
to
drive
rolls
as
pos
sible
without
touching.
Install
nozzle.
Reinstall
gun
(see
Section
3-4).
Thread
welding
wire
(see
Section
3-7).
Close
door.
Ret.
ST.154 624-A
/
ST-801
149
7
7
Remove
nozzle,
contact
tip,
and
liner
collet.
out
gun
casin
Gun/Feeder
COnnector
7
-
Remove
liner.
1~
Tools
Needed:
~
3/8
in
OM-157
066
Page
15
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Miller AUTO ARC 255 Owner's manual

AUTO ARC 255
Miller
Brand
Miller
Model
AUTO ARC 255
Category
Welding System
Type
Owner's manual
This manual is also suitable for

Miller AUTO ARC 255 is a versatile welding power source and wire feeder designed for GMAW and FCAW welding processes. It delivers 200 amps at 28 volts DC with a duty cycle of 60%, making it suitable for various welding applications. The AUTO ARC 255 handles wire diameters ranging from .023 to .045 for hard wire and .030 to .045 for flux-cored wire. It comes equipped with a gun and shielding gas valve, providing a complete welding solution.

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