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 wire welder rated at 200 A welding output with a maximum open-circuit voltage of 28 V DC. It can weld with solid steel, stainless steel, flux-cored, and aluminum wires ranging from 0.023 to 0.045 inches in diameter. The wire feed speed ranges from 90 to 1030 inches per minute. The machine has a compact design with overall dimensions of 37 x 19 x 32 inches and weighs 225 pounds.

Miller AUTO ARC 255 is a wire welder rated at 200 A welding output with a maximum open-circuit voltage of 28 V DC. It can weld with solid steel, stainless steel, flux-cored, and aluminum wires ranging from 0.023 to 0.045 inches in diameter. The wire feed speed ranges from 90 to 1030 inches per minute. The machine has a compact design with overall dimensions of 37 x 19 x 32 inches and weighs 225 pounds.

November
1997
Form:
OM-157
066H
Effective
With
Serial
No.
KH51
1668
OWNERS
MANUAL
Rated
Welding
Output
Amperage
Range
DC
Maximum
Open-Circuit
Voltage
DC
Amperes
Input
at
Rated
Load
Output,
50
or
60
Hz,
Single-Phase
200
V
230
V
KVA
KW
200
A
@
28
Volts
DC,
60%
Duty
Cycle
250A@28VottsDC,40%
Duty
Cycle
40250
42
46
1.1*
40
1.3*
9.5
0.31*
8.3
0.18*
Wire
Type
And
Diameter
Wire
Feed
Speed
Range
Overall
Dimensions
Weight
Solid
Steel
/
Stainless
Steel
Flux
Cored
/
Aluminum
.023
.045
in
(0.6
1.2
mm)
.030
.035
in
(0.8
0.9
mm)
And
3/64
in
(1.2
mm)
Alu
.
90
1030
1PM
(2.9
-26.2
rn/mm)
Length:
37
in
(940
mm)
Width:
19
in
(483
mm)
Height:
32
in
(889
mm)
225
lb
(102
kg)
~While
idling
For
Technical
Support,
Contact:
Milweld
Inc.,
National
Distributor
P.O.
Box
338,
Hortonville,
WI
54944-0338
Tel
920-779-0924
Fax
920-779-0924
Auto
Arcfi
Model
255
Wire
Welder
auto
arc
6/95
ST-157
072-A
PRINTED
IN
USA
This
limited
warranty
supersedes
all
previous
manufacturers
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
below,
warrants
to
its
original
retail
purchaser
that
new
equipment
sold
after
the
effective
date
of
this
limited
warranty
is
free
of
defects
in
material
and
workmanship
at
the
time
it
is
shipped
from
factory.
THIS
WARRANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FITNESS.
Within
the
warranty
periods
listed
below,
manufacturer
will
repair
or
replace
any
warranted
parts
or
components
that
fail
due
to
such
defects
in
material
or
workmanship.
Manufacturer
must
be
notified
in
writing
within
thirty
(30)
days
of
such
defect
or
failure,
at
which
time
manufacturer
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
Manufacturer
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
afailure
within
the
warranty
time
periods.
All
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
or
one
year
after
the
equipment
is
sent
to
the
distributor,
1.
5
Years
Parts
3
Years
Labor
*
Original
main
power
rectifiers
2.
3
Years
Parts
and
Labor
*
Transformer/Rectifier
Power
Sources
*
Plasma
Arc
Cutting
Power
Sources
*
Semi-Automatic
and
Automatic
Wire
Feeders
*
Robots
*
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
3.
1
Year
Parts
and
Labor
Motor
Driven
Guns
(wlexception
of
Spoolmate
185)
Process
Controllers
Positioners
and
Controllers
Automatic
Motion
Devices
Orbital
Weld
Heads
Water
Coolant
Systems
HF
Units
Grids
*
Spot
Welders
*
Load
Banks
*
SDX
Transformers
*
Running
Gear/Trailers
*
Field
Options
(NOTE:
Field
options
are
covered
under
the
limited
warranty
far
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
minimum
of
one
year
whichever
is
greater.)
6
Months
Batteries
90
Days
Parts
and
Labor
*
MIG
Guns/TIG
Torches
*
Plasma
Cutting
Torches
*
Remote
Controls
*
Accessory
Kits
*
Replacement
Parts
*
Spoolmate
185
Limited
Warranty
shall
not
apply
to:
1.
Items
furnished
by
manufacturer,
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactors,
relays,
brushes,
slip
rings,
or
parts
that
fail
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
other
than
manufacturer,
or
equipment
that
has
been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
orequipment
which
has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MANUFACTURERS
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT.
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be,
at
manufacturers
option:
(1)
repair;
or
(2)
replacement;
or,
where
authorized
in
writing
by
manufacturer
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
service
station;
or
(4)
payment
of
or
credit for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk
and
expense.
manufacturers
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
an
authorized
service
facility
as
determined
by
manufacturer.
Therefore
no
compensation
or
reimbursement
for
transportation
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
MANUFACTURER
BE
LIABLE
FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CONTRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MANUFACTURER
IS
EXCLUDED
AND
DISCLAIMED
BY
MANUFACTURER.
Some
states
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.
This
warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state
to
state.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
extent
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.
Warranty
Etteclive
January
1,
1907
(Equipment
with
a
serial
number
preface
of
10
or
newer)
4.
5.
brand_warr
5/97
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
OM-157
066G
3/97
safety_somi
4/95
1-1.
Symbol
Usage
AA
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
I
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.
Arc
Welding
Hazards
a
WARNING
The
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.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
in
the
Safety
Standards
listed
in
Section
1-4.
Read
and
follow
all
Safety
Standards.
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
During
operation,
keep
everybody,
especially
children
away.
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
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
191
0.147
(see
Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
Always
verify
the
supply
ground
check
and
be
sure
that
input
oower
cord
around
wire
is
orooerlv
connected
to
around
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
7.
When
making
input
connections,
attach
proper
grounding
conductor
first
double-check
connections.
8.
Frequently
inspect
input
power
cord
for
damage
or
bare
wiring
replace
cord
immediately
if
damaged
bare
wiring
can
kill.
9.
Turn
off
all
equipment
when
not
in
use.
10.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable
do
not
use
work
clamp
or
work
cable.
13.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
14.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
15.
Wear
a
safety
harness
if
working
above
floor
level.
16.
Keep
all
panels
and
covers
securely
in
place.
17.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
worktable
as
near
the
weld
as
łractical.
A
Marks
a
special
safety
message.
~
Means
NOTE;
not
safety
related.
ARC
RAYS
can
burn
eyes
and
skin;
ARC
RAYS
NOISE
can
damage
hearing;
FLYING
~
SLAG
OR
SPARKS
can
injure
eyes.
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Arc
rays
from
the
welding
process
produce
intense
Z49.1
and
Z87.1
listed
in
Safety
Standards).
visible
and
invisible
(ultraviolet
and
infrared)
rays
3.
Wear
approved
safety
glasses
with
side
shields.
that
can
burn
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Chipping,
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
grinding,
and
welds
cooling
throw
off
pieces
of
and
glare;
warn
others
not
to
watch
the
arc.
metal
or
slag.
NOISE
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
material
(wool
and
leather)
and
foot
protection.
I
FUMES
AND
GASES
can
be
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
hazardous
to
your
health.
wearing
an
air-supplied
respirator.
Always
have
a
trained
watchperson
nearby.
Welding
fumes
and
gases
can
displace
air
I
~
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be hazardous
to
your
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
health.
breathing
air
is
safe.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes,
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
4.
Read
the
Material
Safety
Data
Sheets
(MSDS5)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturers
instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
cleaners,
and
degreasers.
containing
these
elements
can
give
off
toxic
fumes
if
welded.
OM-157
066
Page
1
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,
slag,
open
flames,
sparks,
and
arcs.
2.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
5.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
6.
Never
weld
on
a
pressurized
cylinder
explosion
will
result.
7.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
8.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
9.
Keep
protective
cap
in
placeover
valve
except
when
cylinder
is
in
use
or
connected
for
use.
10.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
WELDING
can
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
cause
them
to
blow
up.
Sparks
can
fly
off
from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
to
metal
oblects
can
cause
sparks,
explosion,
overheating,
or
fire.
Check
and
be
sure
the
area
is
safe
before
doing
any
welding.
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
7.
Do
not
weld
on
closed
containers
such
as
tanks,
drums,
or
pipes,
unless
they
are
properly
prepared
according
to
AWS
F4.
1
(see
Safety
Standards).
8.
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
hazards.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
10.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
1-3.
Additional
Installation,
Operation,
And
Maintenance
Hazards
FIRE
OR
EXPLOSION
can
result
from
placing
unit
on,
over,
or
combustible
surfaces.
1.
Do
not locate
unit
on,
over,
or
near
surfaces.
2.
Do
not
install
unit
near
flammables.
FALLING
EQUIPMENT
can
cause
serious
personal
injury
and
equipment
damage.
1.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
Use
equipment
of
adequate
capacity
to
lift
unit.
If
using
lift
forks
to
move
unit,
be
sure
forks
are
long
enough
to
extend
beyond
opposite
side
of
unit.
HOT
PARTS
can
cause
severe
burns.
Do
not
touch
hot
parts
bare
handed.
Allow
cooling
period
before
working
on
gun
or
torch.
MOVING
PARTS
can
cause
injury.
1.
Keep
away
from
moving
parts
such
as
fans.
2.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
MOVING
PARTS
can
cause
injury.
1.
Keep
away
from
moving
parts.
2.
Keep
away
from
pinch
points
such
as
drive
rolls.
FLYING
PIECES
OF
METAL
or
DIRT
can
injure
eyes.
1.
Wear
safety
glasses
with
side
shields
or
face
shield.
HIGH-FREQUENCY
RADIATION
can
interfere
with
radio
navigation,
safety
services,
computers,
and
communications
equipment.
1.
Have
only
qualified
persons
familiar
with
electronic
equipment
perform
this
installation.
2.
The
user
is
responsible
for
having
a
qualified
electrician
promptly
correct
any
interference
problem
resulting
from
the
installation.
3.
If
notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.
4.
Have
the
installation
regularly
checked
and
maintained.
5.
Keep
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.
near
WELDING
WIRE
can
cause
puncture
wounds.
1.
Do
not
press
gun
trigger
until
instructed
to
do
so.
2.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
~~Jj,J
OM-157
066
Page
2
OVERUSE
can
cause
OVERHEATED
EQUIPMENT.
1.
Allow
cooling
period.
2.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again.
Follow
rated
duty
cycle.
STATIC
ELECTRICITY
can
damage
parts
on
circuit
boards.
SIGNIFICANT
DC
VOLTAGE
exists
after
removal
of
input
power
on
inverters.
1.
Turn
Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
touching
any
parts.
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
1.
Shut
off
shielding
gas
supply
when
not
in
use.
1-4.
Principal
Safety
Standards
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
Use
proper
static-proof
bags
and
boxes
to
store,
-
move,
or
ship
PC
boards.
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.1,
from
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Highway,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wil
7.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
American
Welding
Society
Standard
AWS
F4.1,
from
American
Welding
Society,
550
NW.
LeJeune
Rd,
Miami,
FL
33126
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
51B,
from
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
MA
02269.
1-5.
EMF
Information
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
Electric
And
Magnetic
Fields
procedures:
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
1.
Keep
cables
close
together
by
twisting
or
taping
them.
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
Background
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
Government
Printing
Office,
May
1989):
...
there
is
now
a
very
3.
Do
not
coil
or
drape
cables
around
the
body.
large
volume
of
scientific
findings
based
on
experiments
at
the
cellular
level
and
from
studies
with
animals
and
people
which
clearly
4.
Keep
welding
power
source
and
cables
as
far
away
as
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
practical.
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
possible.
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
About
Pacemakers:
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
The
above
procedures
are
also
recommended
for
pacemaker
or
avoid
potential
risks.
wearers.
Consult
your
doctor
for
complete
information.
OM-157
066
Page
3
2-1.
Installing
Work
Clamp
SECTION
2-
INSTALLATION
5
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
cover
connection
with
boot.
4
Hardware
5
Work
Clamp
Route
cable
through
clamp
handle
and
secure
as
shown.
Close
door.
2
2-2.
Installing
Gas
Supply
Tools
Needed:
~==:::~
1/2,3/4
in
ST-800
918-B
Chain
gas
cylinder
to
running
gear,
wall,
or
other
stationary
support
so
cylinder
cannot
fall
and
break
off
valve.
1
Regulator/Flow
Gauge
Install
so
face
is
vertical.
2
Gas
Hose
Connection
Fitting
has
5/8-18
right-hand
threads.
Argon
Gas
ORQ
3
Flow
Adjust
Typical
flow
rate
is
20
cfh
(cubic
feet
per
hour).
Check
wire
man
ufacturers
recommended
flow
rate.
This
flow
gauge
can
be
adjusted
between
5
and 25
cfh.
4
CO2
Adapter
Customer
Supplied
5
0-Ring
Install
adapter
with
0-ring
between
regulator/flow
gauge
and
CO2
cylinder.
Tools
Needed:
~=~=r
5/8,1-1/8in
ST-i
54
623-A
/
Ret.
ST-i
09492
OM-157
066
Page
4
2-3.
Installing
Welding
Gun
1
Drive
Assembly
2
Gun
Securing
Knob
3
Gun
End
Loosen
securing
knob.
Insert
gun
end
through
opening
until
it
bot
toms
against
drive
assembly.
Tighten
nut.
4
Gun
Trigger
Plug
Insert
plug
into
receptacle,
and
tighten
threaded
collar.
Close
door.
Ref.
ST-801
677
2-4.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
OM-157
066
Page
5
2-5.
Setting
Gun
Polarity
~
~
1
~d~eE~:
Label
_________________________
Assembly)
Always
read
and
follow
manufac
tures
recommended
polarity.
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
S~144
449D
Tools
Needed:
~
3/4,11/161n
OM-157
066
Page
6
2-8.
Selecting
A
Location
And
Connecting
Input
Power
A
Do
not
move
or
operate
unit
where
it
could
tip.
1
Rating
Label
Supply
correct
input
power.
2
Plug
3
Receptacle
(Not
Supplied)
Connect
plug
to
receptacle.
4
Line
Disconnect
Device
See
Section
2-7.
A
Special
installation
may
be
required
where
gasoline
or
volatile
liquids
are
present
see
NEC
Article
511
or
CEC
Section
20.
ST-800
923-A
A
Always
connect
grounding
conductor
first.
=
GND/PE.
4
Li
L2
2.
OM-157066Page8
2-9.
Threading
Welding
Wire
Remove
gun
nozzle
and
contact
tip.
POWER
-4-8
O0~~I
Press
gun
trigger
until
wire
comes
out
of
gun.
Reinstall
contact
tip
and
nozzle.
1111
I
II
Feed
wire
to
check
drive
roll
pressure.
lighten
knob
enough
to
prevent
slipping.
Cut
off
wire.
Close
and
latch
door.
Tools
Needed:
Wire
Spool
Welding
Wire
Inlet
Wire
Guide
4
Pressure
Adjustment
Knob
Drive
Roll
Outlet
Wire
Guide
Gun
Conduit
Cable
Lay
gun
cable
out
straight.
Open
pressure
assembly.
Pull
and
hold
wire;
cut
off
end.
Push
wire
thru
guides
into
gun;
continue
to
hold
wire.
Close
and
tighten
pressure
assembly,
and
let
go
of
wire.
Ref.
5T-801
677
/
S-0627-A
OM-157
066
Page
9
SECTION
3-
OPERATION
3-1.
Front
Panel
Controls
3-2.
Center
Battle
Controls
1
Wire
Mode
Switch
For
better
control
of
wire
speed
use
the
Low
position
when
wire
speed
is
between
90 and
670
ipm.
Use
the
Full
position
when
wire
speed
is
between
150
ipm
and
1030
ipm.
2
Voltage
Range
Selector
Place
switch
in
desired
position.
I~ef.
ST-800919/S-171
601
OM-157
066
Page
10
3-3.
Duty
Cycle
And
Overheating
%
DUTY
CYCLE
Duty
Cycle
is
percentage
of
10
minutes
that
unit
can
weld
at
rated
load
without
overheating.
If
unit
overheats,
thermostat(s)
opens,
output
stops,
and
cooling
fan
runs.
Wait
fifteen
minutes
for
unit
to
cool.
Reduce
amperage
or
voltage,
or
duty
cycle
before
welding.
A
Exceeding
duty
cycle
can
damage
unit
and
void
warranty.
Overheating
60%
Duty
Cycle
At
200
Amperes
6
Minutes
Welding
~AorV
Reduce
Duty
Cycle
dutyl
4/95SB-150
215
300
RATED
OtJrPUT-1
250
200
U)
w
w
-J
w
150
~---
~E~E~E~J
I
-
I
-
!~E
100
20
30 40
60
60
70
8060100
4
Minutes
Resting
4
Minutes
-,~
OM-157
066
Page
11
SECTION
4-
MAINTENANCE
&
TROUBLESHOOTING
4-1.
Routine
Maintenance
4-2.
Circuit
Breaker
CB1
OM-157
066
Page
12
4-3.
Fuses
Fl
And
F2
A
Turn
Off
unit,
and
dis
connect
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.
Toots
Needed:
c::::::::J=::=il:
3/8
in
Ret.
ST-8.QO
928-B
OM-157
066
Page
13
4-6.
Troubleshooting
riH*~
rn~~
Welding
Trouble
Remedy
No
weld
output;
wire
does
not
feed.
Secure
power
cord
plug
in
receptacle
(see
Section
2-8).
Reset
circuit
breaker
CB1
(see
Section
4-2).
Replace
fuse
Fl
and/or
F2
(see
Section
4-3).
Replace
building
line
fuse
or
reset
circuit
breaker
if
open
(see
Section
2-8).
Secure
gun
trigger
plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch
(see
Section
2-3).
Thermostat
TP1
open
(overheating).
Allow
fan
to
run;
the
thermostat
will
close
when
the
unit
has
cooled
(see
Section
3-3).
No
weld
output;
wire
feeds.
Connect
work
clamp
to
get
good
metal
to
metal
contact.
Replace
contact
tip
(see
Gun
Owners
Manual).
Low
weld
output.
Connect
unit
to
proper
input
voltage
or
check
for
low
line
voltage
(see
Section
2-8).
Wire
Drive/Gun
Trouble
Remedy
Electrode
wire
feeding
stops
during
welding.
~
Straighten
gun
cable
and/or
replace
damaged
parts
(see
Gun
Owners
Manual).
Adjust
drive
roll
pressure
(see
Section
2-9).
Readjust
hub
tension
(see
Section
2-4).
Replace
contact
tip
if
blocked
(see
Gun
Owners
Manual).
Clean
or
replace
wire
inlet
guide
or
liner
if
dirty
or
plugged
(see
Gun
Owners
Manual).
Replace
drive
rolls
if
worn
or
slipping
(see
Section
4-4).
Secure
gun
trigger
plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch
(see
Section
2-3).
Check
and
replace
Fl
and/or
F2
(see
Section
4-3).
Check
and
clear
any
restrictions
at
drive
assembly
and
liner
(see
Gun
Owners
Manual).
Have
nearest
Factory
Authorized
Service
Agent
check
drive
motor.
OM-157
066
Page
15
SECTION
5-
ELECTRICAL
DIAGRAM
For
Primary
Circuit
Diagram
Portion,
refer
to
Circuit
Diagram
located
inside
the
wrapper
of
the
welding
power
source.
SB-173
544-D
54
n-~
____
__
1ft~
~I~
__
A
AAAA
1
___
r4::3-~>~
2
Ei
~3-11
>>~~~-<
3
I
~3-1
4~J
5
7
R:3-~>>
rl
Figure
5-1.
Circuit
Diagram
For
Welding
Power
Source
OM-157
066
Page
16
~T
Hardware
is
common
and
not
available
unless
listed.
SECTION
6-
PARTS
LIST
NOTE:
All
items
indented
by
a
dot(s)
are
included
with
the
item
listed
directly
above.
Item
Part
No.
No.
Description
1
146
168
Enclosure Panel
083
526
Housing
Rcpt
&
Sockets
2
Fig
6-2
Baffle
w/Cmpts
3
171
658
Transformer
4
602
250
Washer,
flat
5
070
799
Wheel
6
171
213
Stabilizer
7
Rear
Panel
w/Cmpts
148 808
Fan
Motor
150
783
Fan
Blade
049
399
Speed
Nut
116996
GasValve
605
227
Nylon
Nut,
.750
146524
Hose
149332
Hose
Clamp
152
742
Rectifier
048
420
Capacitor
037
957
Diode,
RP
037
956
Diode,
SP
605886
Washer,
.750
605
884
Half
Nut,
.750-16
171
600
Thermostat,
NC
026
947
Stand-Off
Item
Part
No.
No.
Description
152
862
Grommet
009
970
Rectifier
Bracket
143810
RearPanel
169654
Tank
Bracket
Support
044 426
Cable
Clamp
8
602
387
Cylinder
Chain
9
146165
Side
Panel,LH
10
089899
Latch
11
146167
Side
Panel
12
134
464
Warning
Label
13
+170
513
Wrapper
14
047
721
Cord
Set
15
146161
Base
16
135390
Axle
17
121
614
Retaining
Ring
18
091
685
Resistor
605741
Clip
19
602213
Lock
Washer
20
008
999
Caster
21
601
871
Jam
Nut
22
Front
Panel
w/Cmpts
160
775
Light
035
897
Potentiometer
I
Item
Part
J
No.
No.
Description
097
924
Knob
048
282
Receptacle
w/Sockets
128
755
Switch,
DPST
153
197
Selector
Switch
148956
Switch
Handle
175060
Front
Panel
155
418
Front
Control
Panel
171
639
Control
Plate
174842
Nameplate
144
127
Cover,
module
opening
057357
Bushing,
1.l25mtg
143974
Handle
See
Gun
Owners
Manual
183581
Gas
Hose
600318
Weld
Cable
130
750
Ground
Clamp
173
374
Regulator/Flowmeter
+When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
Be
sure
to
provide
Model
and
Serial
Number
when
ordering
replacement
parts.
Figure
6-1.
Main
Assembly
ST-800
930-C
23
OM-157
066
Page
17
NOTE:
All
items
indented
by
a
dot(s)
are
included
with
the
item
listed
directly
above.
Item
Part
No.
No.
Description
1
174
861
Drive
Assembly,
(Fig
6-3)
2
148956
Switch
Handle
3 021
469
Danger
Label
4
144933
Access
Door
5
058
427
Retaining
Ring
6
085980
Nut
7
605
941
Flat
Washer
8
057
543
Spring,
.845
OD
9
057971
Keyed
Washer
10
010
191
Fiber
Washer
11
058628
Brake
Washer
12
057
745
Spring,
2.430
OD
13
058
428
Hub,
spool
14
177307
Support
Reel
15
174812
Baffle
I
Item
Part
j
No.
No.
Description
16
083147
Grommet
17
082 902
Strip,
mtg
center
18
092
186
Strip,
mtg
LH
&
RH
19
156517
Capacitor
20
186355
Contactor
114786
Link
21
134
201
PC
Card
Stand-Off
22
173002
Motor
Speed
Control
Card
23
*012
658
Fuse,
mintr
gI
slo-blo
2A
125V
23
*073
426
Fuse,
mintr
gI
slo-blo
5A
125V
165
896
Connector
&
Sockets
135
558
Connector
&
Sockets
165
745
Connector
&
Sockets
Item
Part
]
No.
No.
Description
24
083
431
Circuit
Breaker
25
011
609
Toggle
Switch,
SPDT
26
171
610
Selector
Switch
27
153
322
Terminal
Assembly,
pri
2V
038618
Link
28
010199
Tubing
29
039
047
Output
Terminal,
red
30
039
046
Output
Terminal,
black
128
750
Capacitor
31
071
971
Cover
OPTIONAL
*Recommended
Spare
Parts
Be
sure
to
provide
Model
and
Serial
Number
when
ordering
replacement
parts.
2
p3
Fig
6-3
~H~17
19
20
-21
31
30
29
27
Figure
6-2.
Baffle
w/Components
(Fig
6-1
Item
3)
ST-800
931-8
OM-157
066
Page
18
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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 wire welder rated at 200 A welding output with a maximum open-circuit voltage of 28 V DC. It can weld with solid steel, stainless steel, flux-cored, and aluminum wires ranging from 0.023 to 0.045 inches in diameter. The wire feed speed ranges from 90 to 1030 inches per minute. The machine has a compact design with overall dimensions of 37 x 19 x 32 inches and weighs 225 pounds.

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