Got a miller 255 a few months ago and going to try pulse welding next week with it.
Anyone have any pointers?

I have a AHP alpha tig, only tired it a couple times, there are some good videos on youtube that show good setup and examples....I know that's not very helpful...:). I did get a new water cooled torch setup last month but haven't used it yet

I have a Lincoln Square Wave for tig.
The setup for pulse welding is totally different.
Miller 255 has a large number of computer setting, built in.
It took me over a month to find out that the gas was set for c10 not c25. Auto set for c10 is much hotter than the setting for c25.

Pushed some buttons on the welders key pad, hooked up a bottle of c10 gas and tried it out.
Almost no splatter and the welds look good.

Glad it worked for you. --- I still fight wire welding----never did get it down pat! lol!

I still have not got tig down, but am getting close to J hook with wire.
Welded stick for 25 years, but have been wire for the last 20.
Most weeks, I measure the amount of welds I do in a week, by the 100's of feet.

Welded up a sample item yesterday. 10ga steel, over 100" of weld.
I welded just about every way I could.
Pulse, mig (c20), mig (c10), push, pull, etc.
The mig c10 work the best and it did not matter which way I ran the bead.

It will take time to figure out the best way to go at it. I only have stick, wire, and oxy/acy. here to weld and braze with, so I am of no help on this new stuff!

I have a Lincoln square wave as well, I only use the pulse because it helps with my lousy wire feeding, I was cursed at birth with no rhythm. I have been curious about pulsed mig but have never had a chance to try it. I am friends with the outside sales guy for the local welding supplier in the town were I work and he has brought several machines and hoods out for me to demo, I'll have to drop a bug in his ear and get him to bring one out when he can. is the pulse with mig to control heat input to the material only or does it serve other functions? It seems like it would be good for up hill to freeze the puddle to take out some sagging but I really haven't looked into it because it is out of my price range. are you liking it as compared to normal mig with c-25?

Normal mig with c10 gas is giving me the best welded.
I got 100'+ of bead to lay on 1/4" steel this week and I will try all the setting the 255 has.
Over the weekend I welded over 20' of bead, on 1/2" x 1/2" x 14ga tube.
60 pieces for 6 small gates, in 1 1/2 hours.
Have 27 more of the gates to build in the next week.
Used the normal mig c10 setting and the welds went down fast and clean. I did set the autoset for 16ga, not 14ga.
At 14ga setting, if the gap at the joint was over 1/16", it would sometimes blowout.
Got around 10000" of cut to do with the cnc plasma cutter today, then back to welding.

I had the Miller XMT300 multiprocess inverter welder for over 25yrs, it did CC(stick) and CV(MIG) and did them very well..worked on single or three phase,awesome for 1990s technology..It had the 'inductance' control on it which let you freeze the puddle of the weld and make it 'run cooler' without changing your wire speed/voltage ratio..I ran .035 wire on everything from thin sheet metal to heavy structural..after 25yrs it blew up one day in a cloud of smoke,quite literally.
Now I'm back to an CP250 MIG power supply using my old feeder, 100%duty cycle machine, without the inductance control..Im not sure if the inductance control is a form of pulse welding or not,but it sure did make thin metal easy to work with,I sure miss it..

The 255 should be able to do most anything you want to do..what wire size are you using with it?

On wire size, 1/4" steel and up, I use .045 most of the time.
Then use .035 on the thinner metal.
I did get the .030 feed rollers for the 255 and have a roll of .030 wire, but have not try it yet.
Running way behind this fall, I have app 50 signs that should of been mailed out last week and I still do not have them powder coated.
Got to weld up fire pits today, 15 will be pickup tomorrow. So, I will see if I can learn anything else about the setting on my 255.

just finishing up my 0900am break..I use .035 wire for just about everything..take a look over at millerwelds.com they have a forum..probably some people over there using a 255 as well with some setting suggestions..I sure miss the digital readout for MIG voltage,this old CP250 I'm using has quite the vague slide indicator for voltage..not too precise..but for me the old skewl machines get the job done

Got all the Christmas orders out, plus a set of 10 sheep pens today.
Still have 2 off ground dog kennels to weld up this coming week, plus 3-4 weeks of work on other orders to do.
The c10 gas cost the same as the c25 gas does and for me the c10 gas gives a much better looking weld.
As for pulse welding, I am still working on the right setting. The big draw back is it is 4-5 times as loud. You need ear plugs.

sounds like you been keepin busy !