July 1995 Form: OM-116J Effective With Serial No. KF943539 OWNER’S MANUAL Thunderbolt 225 CC/AC Welding Power Source For SMAW (Stick) Welding Rated Welding Output Amperage Range Maximum OpenCircuit Voltage Amperes Input at Rated Load Output 60 Hz, Single-Phase Overall Dimensions 230 V KW 47.5 (8.6)* 7.2 (0.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING safety_stickom1 6/95 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks 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.
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. WELDING explosion. can cause fire or 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.
SECTION 2 – INSTALLATION NOTE See User’s Guide on unit for process connection information. 2-1. Selecting A Location And Installing Handle 1 Lifting Area Place hands where shown to move unit. Get help when moving unit. 2 3 5 6 Running Gear Mounting Holes Rating Label Locate unit near correct input power. 4 4 5 6 Amperage Adjustment Rod Handle Pin Install as shown. Move pin into locked position shown. 1 Locked Pin 3 18 in (457 mm) for airflow 2 ST-052 359-D / Ref.
2-3. Connecting Input Power Y Have only qualified persons make this installation. L1 L2 GND/PE 230 VAC, 1 GND/PE L1 L2 GND/PE Connect First Tools Needed: Minimum input and grounding conductor size is 10 AWG/Kcmil, not to exceed 87 ft (26 m) in length. Install conductors in conduit or equivalent into a deenergized line disconnect device. Maximum recommended standard fuse or circuit breaker rating is 70 amperes. Size and ratings must comply with applicable codes. 3/8 in ssb2.
SECTION 3 – OPERATION 3-1. Controls 1 2 3 4 Amperage Control Amperage Range Indicator Electrode (30–150 A) Weld Output Receptacle Electrode (40–225 A) Weld Output Receptacle When welding below 150 amps, use 30–150 A receptacle. 5 6 Work Weld Output Receptacle Power Switch 1 2 3 4 6 5 Ref. ST-155 574 / Ref. SC-107 516-F 3-2. Duty Cycle Chart And Volt-Ampere Curves Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Y 20% Duty Cycle at 225 Amperes.
SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Repair Or Replace Cracked Cables Replace Unreadable Labels Clean And Tighten Weld Connections 6 Months 12 Months Blow Out Or Vacuum Inside, During Heavy Service, Clean Monthly OR Lubricate Shunt Block 4-2. Lubricating Shunt Block And Anti-Noise Adjustment Y Turn Off welding power source and disconnect input power.
4-3. Troubleshooting Trouble Remedy No weld output; fan does not run. Be sure line disconnect switch is in On position (see Section 2-3). Check and replace line fuses if open. Reset breakers if necessary (see Section 2-3). Fan does not run; weld output okay. Be sure nothing is blocking movement of fan. If fan does not run freely, replace fan motor. Erratic weld current. Clean and tighten all weld cable connections. Erratic arc with excessive spatter. Use dry, properly stored electrodes.
SECTION 6 – PARTS LIST Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1. Main Assembly . . . 1 . . . . . . . . . . 039 800 . . RECEPTACLE, jack plug red (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . 006 095 . . . . RECEPTACLE & NUT, jack plug red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . 010 291 . . . . WASHER, flat nylafil .625 ID x 1.250 OD x .125thk . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-2. Transformer & Shunt (Fig 6-1 Item 17) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 . . . . . . . . . . . 080 522 . . . . . . . . . . . 147 907 . . . . . . . . . . . 112 569 . . . SEC . . . 112 488 . . . . . . . . . . . 119 962 . . . . . . . . . +081 821 . . . . . . . . . +009 312 . . . . . . . . . . . 601 860 . .
OPTIONS AND ACCESSORIES No. 11A RUNNING GEAR (#041 637) A handle and two wheels with solid rubber tires mount easily to the frame of the Thunderbolt 225, providing convenient portability.
Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number.
