July 1995 Form: OM-116J

Effective With Serial No. KF943539

OWNER’S
MANUAL

Thunderbolt 225
CC/AC Welding Power Source For SMAW (Stick) Welding

Amperes Input
Maximum at Rated Load
Rated
Amperage Open- Output 60 Hz,
Welding Overall Dimensions Weight
Range Circuit Single-Phase
Output
Voltage
230 V KW
Height: 21-1/2 in (546 mm)
225 A @ 25 Low: 30 – 150A Net: 100 lb (45 kg)
47.5 7.2
Volts AC, 20% 80 VAC Width: 12-1/2 in (318 mm)
(8.6)* (0.22)*
Duty Cycle High: 40 – 225A Ship: 105 lb (48 kg)
Depth: 14 in (356 mm)
*While idling
cover_om 4/95 – ST-052 359-D  1995 MILLER Electric Mfg. Co. PRINTED IN USA
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.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
Working as hard as you do
This Owner’s Manual is designed to help you get the most out of your – every power source from
Miller is backed by the most
Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the
help you protect yourself against potential hazards on the worksite. We’ve business.

made installation and operation quick and easy.

With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
Miller is the first welding figure out what the problem is. The parts list
equipment manufacturer in will then help you to decide which exact part
the U.S.A. to be registered to
the ISO 9001 Quality System you may need to fix the problem. Warranty and
Standard. service information for your particular model
are also provided. Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
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 Y Marks a special safety message.
procedure! The possible hazards are shown in the adjoining symbols. . 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. Arc Welding Hazards

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. in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is 7. When making input connections, attach proper grounding
electrically live whenever the output is on. The input conductor first – double-check connections.
power circuit and machine internal circuits are also 8. Frequently inspect input power cord for damage or bare wiring –
live when power is on. Incorrectly installed or replace cord immediately if damaged – bare wiring can kill.
improperly grounded equipment is a hazard.
9. Turn off all equipment when not in use.
1. Do not touch live electrical parts. 10. Do not use worn, damaged, undersized, or poorly spliced cables.
2. Wear dry, hole-free insulating gloves and body protection. 11. Do not drape cables over your body.
3. Insulate yourself from work and ground using dry insulating mats 12. If earth grounding of the workpiece is required, ground it directly
or covers big enough to prevent any physical contact with the with a separate cable – do not use work clamp or work cable.
work or ground. 13. Do not touch electrode if you are in contact with the work, ground,
4. Disconnect input power before installing or servicing this or another electrode from a different machine.
equipment. Lockout/tagout input power according to OSHA 29 14. Use only well-maintained equipment. Repair or replace damaged
CFR 1910.147 (see Safety Standards). parts at once. Maintain unit according to manual.
5. Properly install and ground this equipment according to its 15. Wear a safety harness if working above floor level.
Owner’s Manual and national, state, and local codes. 16. Keep all panels and covers securely in place.
6. Always verify the supply ground – check and be sure that input 17. Clamp work cable with good metal-to-metal contact to workpiece
power cord ground wire is properly connected to ground terminal or worktable as near the weld as practical.

ARC RAYS can burn eyes and skin; ARC RAYS

NOISE can damage hearing; FLYING 2. Wear a welding helmet fitted with a proper shade of filter to protect
SLAG OR SPARKS can injure eyes. your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
Arc rays from the welding process produce intense
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, grinding, 4. Use protective screens or barriers to protect others from flash
and welds cooling throw off pieces of metal or slag. and glare; warn others not to watch the arc.
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.

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
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 (MSDSs) 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-116J – 7/95 OM-116 Page 1

 CYLINDERS can explode if damaged. 1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since 2. Keep cylinders away from any welding or other electrical circuits.
gas cylinders are normally part of the welding 3. Never drape an electrode holder over a gas cylinder.
process, be sure to treat them carefully. 4. Never allow a welding electrode to touch any cylinder.
5. Never weld on a pressurized cylinder – explosion will result.

WELDING can cause fire or 5. Watch for fire, and keep a fire extinguisher nearby.
explosion. 6. Be aware that welding on a ceiling, floor, bulkhead, or partition
Welding on closed containers, such as tanks, can cause fire on the hidden side.
drums, or pipes, can cause them to blow up. Sparks 7. Do not weld on closed containers such as tanks, drums, or pipes,
can fly off from the welding arc. The flying sparks, unless they are properly prepared according to AWS F4.1 (see
hot workpiece, and hot equipment can cause fires Safety Standards).
and burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, 8. Connect work cable to the work as close to the welding area as
or fire. Check and be sure the area is safe before practical to prevent welding current from traveling long, possibly
doing any welding. unknown paths and causing electric shock and fire hazards.
1. Protect yourself and others from flying sparks and hot metal. 9. Do not use welder to thaw frozen pipes.
2. Do not weld where flying sparks can strike flammable material. 10. Remove stick electrode from holder when not in use.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If 11. Wear oil-free protective garments such as leather gloves, heavy
this is not possible, tightly cover them with approved covers. shirt, cuffless trousers, high shoes, and a cap.
4. Be alert that welding sparks and hot materials from welding can 12. Remove any combustibles, such as a butane lighter or matches,
easily go through small cracks and openings to adjacent areas. from your person before doing any welding.

1-3. Additional Installation, Operation, And Maintenance Hazards

FIRE OR EXPLOSION can result from MAGNETIC FIELDS FROM HIGH
placing unit on, over, or near CURRENTS can affect pacemaker
combustible surfaces. operation.
1. Do not install unit on, over, or near combustible 1. Wearers should consult their doctor before going
surfaces or flammables. near arc welding, gouging, or spot welding
operations.
HOT PARTS can cause severe burns. FLYING PIECES OF METAL or DIRT can
1. Do not touch hot parts bare handed. Allow cooling injure eyes.
period before beginning. 1. Wear safety glasses with side shields or face
shield.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American National Electrical Code, NFPA Standard 70, from National Fire
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Protection Association, Batterymarch Park, Quincy, MA 02269.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Safety and Health Standards, OSHA 29 CFR 1910, from Canadian Standards Association, Standards Sales, 178 Rexdale
Superintendent of Documents, U.S. Government Printing Office, Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Washington, D.C. 20402.
Safe Practices For Occupation And Educational Eye And Face
Recommended Safe Practices for the Preparation for Welding and Protection, ANSI Standard Z87.1, from American National Standards
Cutting of Containers That Have Held Hazardous Substances, Institute, 1430 Broadway, New York, NY 10018.
American Welding Society Standard AWS F4.1, from American Cutting And Welding Processes, NFPA Standard 51B, from National
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 Fire Protection Association, Batterymarch Park, Quincy, 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:
1. Keep cables close together by twisting or taping them.
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological 2. Arrange cables to one side and away from the operator.
Effects of Power Frequency Electric & Magnetic Fields – Background
Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing 3. Do not coil or drape cables around the body.
Office, May 1989): “. . . there is now a very large volume of scientific
findings based on experiments at the cellular level and from studies 4. Keep welding power source and cables as far away as
with animals and people which clearly establish that low frequency practical.
magnetic fields can interact with, and produce changes in, biological
systems. While most of this work is of very high quality, the results are 5. Connect work clamp to workpiece as close to the weld as
complex. Current scientific understanding does not yet allow us to possible.
interpret the evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite conclusions about About Pacemakers:
questions of possible risk or to offer clear science-based advice on The above procedures are also recommended for pacemaker
strategies to minimize or avoid potential risks.” wearers. Consult your doctor for complete information.

OM-116 Page 2
 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 Running Gear Mounting Holes
3 Rating Label
5
Locate unit near correct input
power.
6 4
4 Amperage Adjustment Rod
5 Handle
6 Pin
Install as shown.
Move pin into locked position
shown.

1
Locked Pin

18 in (457 mm) for airflow

ST-052 359-D / Ref. ST-151 556 / ST-155 573-A

2-2. Weld Output Cables

NOTE For weld output cable replacements or extensions, contact your Factory
Authorized Service Agent.

OM-116 Page 3
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

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 stan-
dard fuse or circuit breaker rating is 70 amperes. Size
and ratings must comply with applicable codes.
Tools Needed:

3/8 in
ssb2.2 3/93 – ST-155 576-B

OM-116 Page 4
 SECTION 3 – OPERATION
3-1. Controls
1 Amperage Control
2 Amperage Range Indicator
3 Electrode (30–150 A) Weld
Output Receptacle
4 Electrode (40–225 A) Weld
Output Receptacle
When welding below 150 amps,
use 30–150 A receptacle.
5 Work Weld Output Receptacle
6 Power Switch
1
2

3
4 6

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. Ex-
ceeding duty cycle can damage unit
and void warranty. The volt-ampere curves show the minimum and maximum
voltage and amperage output capabilities. Curves of other
settings fall between the curves shown.

2 Minutes Welding 8 Minutes Resting

rduty1 5/95 – ST-001 836-A / ST-001 844-A

OM-116 Page 5
 SECTION 4 – MAINTENANCE & TROUBLESHOOTING
4-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Repair Or
Replace
Replace
Unreadable
Cracked
Labels
Cables

Clean
And
Tighten Weld
Connections

6 Months 12 Months

Blow Out Or Vacuum Lubricate

Inside, Shunt
OR During Heavy Service, Block
Clean Monthly

4-2. Lubricating Shunt Block And Anti-Noise Adjustment

Y Turn Off welding power
source and disconnect input
power.
1 Shunt Block
Apply light coating of high-tempera-
ture grease to shaded areas of both
shunt blocks.
Install amperage control handle
Y Install wrapper before turning On power. and locking pin. Turn handle to
spread grease evenly.
2 Noise Adjustment Screws
If shunt block vibrates and be-
comes noisy, tighten adjustment
screws 1/4 turn. Install wrapper,
handle, and pin, turn On unit, and
check for shunt noise. Repeat pro-
cedure until noise stops. Do not
overtighten. Call your nearest Fac-
tory Authorized Service Agent if
noise continues.
Reinstall wrapper, handle, and pin.
1

2
Tools Needed:
1

ST-155 498-A

OM-116 Page 6
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. See User’s Guide also.
Shorten arc length. See User’s Guide also.
Reduce amperage setting (see Section 3-1).
Electrode freezing to work. Use dry, properly stored electrodes. See User’s Guide also.
Increase arc length. See User’s Guide also.
Increase amperage setting (see Section 3-1).

SECTION 5 – ELECTRICAL DIAGRAM

SA-108 072

Figure 5-1. Circuit Diagram For Welding Power Source

OM-116 Page 7
 SECTION 6 – PARTS LIST

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 6-1. Main Assembly

. . . 1 . . . . . . . . . . 039 800 . . RECEPTACLE, jack plug red (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 2 . . . . . . . . . . 006 095 . . . . RECEPTACLE & NUT, jack plug red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 010 291 . . . . WASHER, flat nylafil .625 ID x 1.250 OD x .125thk . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 604 668 . . . . NUT, stl slflkg hex med fnsh .500-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . 174 491 . . . . WASHER, lock intl tooth .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 601 881 . . . . NUT, stl hex jam .500-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . S1 . *124 511 . . SWITCH, tgl DPST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 088 372 . . CASE SECTION, base/front/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 024 103 . . BLANK, snap-in .750mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . 111 443 . . BUSHING, strain relief .240/.510 ID x .875mtg hole . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 088 297 . . CORD SET, 250V 6-50P 12ga 3/c 6ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 039 778 . . RECEPTACLE, str 2P3W 50A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 005 656 . . BLADE, fan 6 in 4wg 30deg .175 bore CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . FM . . 123 468 . . MOTOR, 230V 50/60Hz 3000RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 082 272 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 009 926 . . PIN, handle control current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 009 433 . . HANDLE, control current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . T1 . . 117 668 . . TRANSFORMER & SHUNT, (230V) (Fig 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 010 142 . . CLAMP, nyl .312clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 174 453 . . HOLDER, electrode w/cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 174 456 . . GROUND CABLE, w/clamp 10ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16
15
4
1 5 10
4 14
3 9
8
Includes 11
Item 2
7

12

13

17 Fig 6-2

19

18
Ref. SD-052 395-E

Figure 6-1. Main Assembly

*Recommended Spare Parts.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-116 Page 8
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 6-2. Transformer & Shunt (Fig 6-1 Item 17)

... 1 . . . . . . . . . . . 080 522 . . . BLOCK, anti-noise shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

... 2 . . . . . . . . . . . 147 907 . . . SCREW, set stl hdls .312-18 x 1.500 slflkg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 3 . . . . . . . . . . . 112 569 . . . INSULATION, coil sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . SEC . . . 112 488 . . . COIL, sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . 119 962 . . . SHUNT, transformer (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . +081 821 . . . . SCREW, slftpg filph 8-11 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . +009 312 . . . . INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . 601 860 . . . . NUT, stl hex 8-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 . . . . . . . . . . . 009 428 . . . . SCREW, lead shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . 021 100 . . . . NUT, lead scr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . 602 087 . . . . SCREW, mach stl rdh 8-32 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 12 . . . . . . . . . . . 036 356 . . . . BLOCK, shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . 119 963 . . . . TUBING, phen .531 ID x .875 OD x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . 020 284 . . . . WEDGE, coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . 010 653 . . . . BEARING, thr oil imprg .375 ID x .750 OD x .062 . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . . . . . . . . 010 929 . . . . WASHER, flat stl spr .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . . . . . . . . . 024 869 . . . . COLLAR, set w/screws (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 . . . . . . . . . . . 024 612 . . . . . . COLLAR, set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 . . . . . . . . . . . 602 176 . . . . . . SCREW, set stl sch .250-20 x .187knr cup point . . . . . . . . . . . . . . . . . . . . 2
... 20 . . . . . . . . . . . 112 573 . . . INSULATION, coil pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 21 . . . PRI . . . 112 498 . . . COIL, pri (230V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 . . . . . . . . . . . 605 129 . . . SCREW, cap stl hexhd .250-20 x 7.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 23 . . . . . . . . . . . 020 300 . . . WEDGE, rear removable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 24 . . . . . . . . . . . 020 301 . . . GUIDE, wedge rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 25 . . . . . . . . . . . 089 800 . . . NUT, stl flg lkd hex .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 26 . . . . . . . . . . . 602 241 . . . WASHER, flat stl SAE .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 9
7
8
10

11
Includes Items
7 thru 19
12

13
20
4
3
2 14 21
15
16
18
17
1 19
22

26 23
25
24
23 ST-052 396-F

Figure 6-2. Transformer & Shunt

+Not part of Shunt Assembly
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-116 Page 9
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.

4/95
 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
Warranty Questions? guarantees or warranties expressed or implied.

Call LIMITED WARRANTY – Subject to the terms and conditions * APT, ZIPCUT & PLAZCUT Model Plasma Cutting
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches
1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold
* Remote Controls
for your local after the effective date of this limited warranty is free of defects
* Accessory Kits
in material and workmanship at the time it is shipped by Miller.
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Replacement Parts (No labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate 185 & Spoolmate 250
Within the warranty periods listed below, Miller will repair or * Canvas Covers
Your distributor also gives replace any warranted parts or components that fail due to
you ... Miller’s True Blue Limited Warranty shall not apply to:
such defects in material or workmanship. Miller must be
Service notified in writing within thirty (30) days of such defect or 1. Consumable components; such as contact tips,
failure, at which time Miller will provide instructions on the cutting nozzles, contactors, brushes, slip rings,
You always get the fast, warranty claim procedures to be followed.
reliable response you relays or parts that fail due to normal wear.
need. Most replacement Miller shall honor warranty claims on warranted equipment
2. Items furnished by Miller, but manufactured by others,
parts can be in your listed below in the event of such a failure within the warranty
such as engines or trade accessories. These items are
time periods. All warranty time periods start on the date that
hands in 24 hours. the equipment was delivered to the original retail purchaser, or
covered by the manufacturer’s warranty, if any.
Support one year after the equipment is sent to a North American 3. Equipment that has been modified by any party other
Need fast answers to the distributor or eighteen months after the equipment is sent to an than Miller, or equipment that has been improperly
International distributor. installed, improperly operated or misused based upon
tough welding questions?
Contact your distributor. 1. 5 Years Parts – 3 Years Labor industry standards, or equipment which has not had
The expertise of the reasonable and necessary maintenance, or equipment
* Original main power rectifiers which has been used for operation outside of the
distributor and Miller is specifications for the equipment.
* Inverters (input and output rectifiers only)
there to help you, every
step of the way. 2. 3 Years — Parts and Labor MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Transformer/Rectifier Power Sources PERSONS TRAINED AND EXPERIENCED IN THE USE
* Plasma Arc Cutting Power Sources AND MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Inverter Power Supplies exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
* Intellitig appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
3. 1 Year — Parts and Labor replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
* Motor Driven Guns (w/exception of Spoolmate transportation costs of any kind will be allowed.
185 & Spoolmate 250)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Process Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Positioners and Controllers REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* RFCS Foot Controls PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources ANY OTHER LEGAL THEORY.
* Water Coolant Systems ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
* HF Units AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Maxstar 140 OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
* Spot Welders OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Load Banks OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
* Miller Cyclomatic Equipment MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
* Running Gear/Trailers EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
* Plasma Cutting Torches (except APT & SAF DISCLAIMED BY MILLER.
Models) Some states in the U.S.A. do not allow limitations of how long
* Field Options an implied warranty lasts, or the exclusion of incidental,
(NOTE: Field options are covered under True indirect, special or consequential damages, so the above
Blue for the remaining warranty period of the limitation or exclusion may not apply to you. This warranty
product they are installed in, or for a minimum of provides specific legal rights, and other rights may be
one year — whichever is greater.) available, but may vary from state to state.

4. 6 Months — Batteries In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,
5. 90 Days — Parts and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
* MIG Guns/TIG Torches Warranty provides specific legal rights, and other rights may
* Induction Heating Coils and Blankets be available, but may vary from province to province.

miller_warr 7/00
 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.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters–USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters –
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com

Contact the Delivering Carrier for: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00