Miller Regeny 250

8/7/2019 Miller Regeny 250

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Regency 250

Processes

Description

R

MIG (GMAW) Welding

Arc Welding Power Source

OM-293 120 243NOctober 2001

Visit our website at

www.MillerWelds.com


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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.

Thank you and congratulations on choosing Miller.

Now you can get the job done and get it done right. We

know you dont have time to do it any other way.

Thats 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 couldnt 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. Theyre just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owners Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.

Weve 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,

theres a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide which

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer inthe U.S.A. to be registered tothe ISO 9001 Quality SystemStandard.

Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.

From Miller to You

Miller offers a TechnicalManual which providesmore detailed service andparts information for yourunit. To obtain a TechnicalManual, contact your localdistributor. Your distributorcan also supply you withWelding Process Manualssuch as SMAW, GTAW,

GMAW, and GMAW-P.


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TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . . . . . . . . . . . . . . . . . .

1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principales normes de scurit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5. Information sur les champs lectromagntiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 INSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Duty Cycle And Overheating 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Volt-Ampere Curves 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Selecting A Location 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Dimensions And Weights 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Weld Output Receptacles And Selecting Cable Sizes 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Remote 14 Receptacle Information 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Electrical Service Guide 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-9. Placing Jumper Links And Connecting Input Power 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 OPERATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Controls 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 MAINTENANCE & TROUBLESHOOTING 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Routine Maintenance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Troubleshooting 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 ELECTRICAL DIAGRAM 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 6 PARTS LIST 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OPTIONS AND ACCESSORIESWARRANTY

OM-293

WARNING

This product, when usedfor welding or cutting,produces fumes orgases which containchemicals known to theState of California tocause birth defects and,in some cases, cancer.(California Health &Safety Code Section25249.5 et seq.)

The following terms areused interchangeablythroughout this manual:MIG = GMAW


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OM-293 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_4/98

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.

Y Marks a special safety message.

. Means Note; not safety related.

This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessary actionsto avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section 1-4. Read and follow allSafety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, thewire, wire reel, drive roll housing, and all metal parts touching thewelding wire are electrically live. Incorrectly installed or improperlygrounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating matsor covers big enough to prevent any physical contact with the workor ground.

D Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present onunit.

D Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

D Always verify the supply ground check and be sure that input

power cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

D When making input connections, attach proper grounding conduc-tor first double-check connections.

D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directlywith a separate cable.

D Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to preventcontact with any metal object.

D Do not connect more than one electrode or work cable to anysingle weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal ofinput power on inverters.

D Turn Off inverter, disconnect input power, and discharge inputcapacitors according to instructions in Maintenance Sectionbefore touching any parts.

Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use exhaust at the arc to removewelding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.

D Read the Material Safety Data Sheets (MSDSs) and themanufacturers instructions for metals, consumables, coatings,cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and if necessary, while wearing anair-supplied respirator. The coatings and any metals containingthese elements can give off toxic fumes if welded.


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OM-293 Page 2

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

ARC RAYS can burn eyes and skin.

D Wear a welding helmet fitted with a proper shade of filter to protectyour face and eyes when welding or watching (see ANSI Z49.1and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under yourhelmet.

D Use protective screens or barriers to protect others from flash andglare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-rial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.

WELDING can cause fire or explosion.

D Protect yourself and others from flying sparks and hot metal.

D Do not weld where flying sparks can strike flammable material.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding caneasily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition cancause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

D Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes.D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or useapproved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun ortorch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.

D Wearers should consult their doctor beforegoing near arc welding, gouging, or spotwelding operations.

NOISE can damage hearing.

Noise from some processes or equipment candamage hearing.

D Wear approved ear protection if noise level ishigh.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-cal shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and fit-tings designed for the specific application; maintain them andassociated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is inuse or connected for use.

D Read and follow instructions on compressed gas cylinders,associated equipment, and CGA publication P-1 listed in Safety

Standards.


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OM-293 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or nearcombustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring be sure power supply system isproperly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift andsupport unit.

D If using lift forks to move unit, be sure forks arelong enough to extend beyond opposite side ofunit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle beforestarting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handlingboards or parts.

D Use proper static-proof bags and boxes tostore, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts.D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to doso.

D Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guardsclosed and securely in place.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

D Have only qualified persons familiar withelectronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

D If notified by the FCC about interference, stop using theequipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-tronic equipment.

D Be sure this welding machine is installed and groundedaccording to this manual.

D If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from AmericanWelding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-dent of Documents, U.S. Government Printing Office, Washington, D.C.20402.

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers That Have Held Hazardous Substances, AmericanWelding Society Standard AWS F4.1, from American Welding Society,550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 1235 Jefferson Davis Highway,Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 RexdaleBoulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And FaceProtection, ANSI Standard Z87.1, from American National StandardsInstitute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from NationalFire Protection Association, Batterymarch Park, Quincy, MA 02269.


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OM-293 Page 4

1-5. EMF Information

Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: The body of evidence, in thecommittees judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.

However, studies are still going forth and evidence continues to beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.

To reduce magnetic fields in the workplace, use the followingprocedures:

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 your body.

4. Keep welding power source and cables as far away from opera-tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-ble.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,then following the above procedures is recommended.


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OM-293 Page 5

SECTION 1 CONSIGNES DE SECURITE LIRE AVANTUTILISATION

som _nd_fre 4/98

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procdureprsente des risques de danger ! Ceux-ci sont identifispar des symboles adjacents aux directives.

Y Identifie un message de scurit particulier.

. Signifie NOTA ; nest pas relatifla scurit.

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a desrisques de danger relis aux CHOCS LECTRIQUES, aux PICES ENMOUVEMENT et aux PICES CHAUDES. Reportez-vous aux symboleset aux directives ci-dessous afin de connatre les mesures prendre pourviter tout danger.

1-2. Dangers relatifs au soudage larc

Y Les symboles prsents ci-aprs sont utiliss tout au long duprsent manuel pour attirer votre attention et identifier les risquesde danger. Lorsque vous voyez un symbole, soyez vigilant etsuivez les directives mentionnes afin dviter tout danger. Lesconsignes de scurit prsentes ci-aprs ne font que rsumerlinformation contenue dans les normes de scuritnumres la section 1-4. Veuillez lire et respecter toutes ces normes descurit.

Y Linstallation, lutilisation, lentretien et les rparations ne doi-vent tre confis qu des personnes qualifies.

Y Au cours de lutilisation, tenir toute personne lcart et plus par-ticulirement les enfants.

UN CHOC LECTRIQUE peut tuer.

Un simple contact avec des pices lectriques peutprovoquer une lectrocution ou des blessures graves.Llectrode et le circuit de soudage sont sous tensionds que lappareil est sur ON. Le circuit dentre et lescircuits internes de lappareil sont galement sous

tension ce moment-l. En soudage semi-automatique ou automatique,le fil, le dvidoir, le logement des galets dentranement et les picesmtalliques en contact avec le fil de soudage sont sous tension. Desmatriels mal installs ou mal mis la terre prsentent un danger.

D Ne jamais toucher les pices lectriques sous tension.

D Porter des gants et des vtements de protection secs ne comportantpas de trous.D Sisoler de la pice et de la terre au moyen de tapis ou d autres

moyens isolants suffisamment grands pour empcher le contact phy-sique ventuel avec la pice ou la terre.

D Ne pas se servir de source lectrique courant lectrique dans les zoneshumides, dans les endroits confins ou l o on risque de tomber.

D Se servir dune source lectrique courant lectrique UNIQUEMENT si leprocd de soudage le demande.

D Si lutilisation dune source lectrique courant lectrique savre nces-saire, se servir de la fonction de tlcommande si lappareil en est quip.

D Couper lalimentation ou arrter le moteur avant de procder linstal-lation, la rparation ou lentretien de lappareil. Dverrouillerlalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes descurit).

D Installer et mettre la terre correctement cet appareil conformment son manuel dutilisation et aux codes nationaux, provinciaux etmunicipaux.

D Toujours vrifier la terre du cordon dalimentation Vrifier et sassu-rer que le fil de terre du cordon dalimentation est bien raccord laborne de terre du sectionneur ou que la fiche du cordon est raccorde une prise correctement mise la terre.

D En effectuant les raccordements dentre fixer dabord le conducteurde mise la terre appropri et contre-vrifier les connexions.

D Vrifier frquemment le cordon dalimentation pour voir sil nest pasendommag ou dnud remplacer le cordon immdiatement sil estendommag un cble dnud peut provoquer une lectrocution.

D Mettre lappareil hors tension quand on ne lutilise pas.D Ne pas utiliser des cbles uss, endommags, de grosseur insuffi-

sante ou mal pisss.D Ne pas enrouler les cbles autour du corps.D Si la pice soude doit tre mise la terre, le faire directement avec un

cble distinct.D Ne pas toucher llectrode quand on est en contact avec la pice, la

terre ou une lectrode provenant dune autre machine.

D Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ les pices endommages. Entretenir lappareil conformment ce manuel.

D Porter un harnais de scurit quand on travaille en hauteur.

D Maintenir solidement en place tous les panneaux et capots.

D Fixer le cble de retour de faon obtenir un bon contact mtal-mtal

avec la pice souder ou la table de travail, le plus prs possible de lasoudure.

D Isoler la pince de masse quand pas mis la pice pour viter le contactavec tout objet mtallique.

Il y a DU COURANT CONTINU IMPORTANT dans lesconvertisseurs aprs la suppression de lalimenta-tion lectrique.D Arrter les convertisseurs, dbrancher le courant lectrique, et d-

charger les condensateurs dalimentation selon les instructionsindiques dans la partie entretien avant de toucher les pices.

Le soudage gnre des fumes et des gaz. Leurinhalation peut tre dangereux pour votre sant.

D Eloigner votre tte des fumes. Ne pas respirerles fumes.

D A lintrieur, ventiler la zone et/ou utiliser un chappement au niveaude larc pour lvacuation des fumes et des gaz de soudage.

D Si la ventilation est insuffisante, utiliser un respirateur alimenta-tion dair homologu.

D Lire les spcifications de scurit des matriaux (MSDSs) et lesinstructions du fabricant concernant les mtaux, les consomma-bles, les revtements, les nettoyants et les dgraisseurs.

D Travailler dans un espace ferm seulement sil est bien ventil ou en

portant un respirateur

alimentation dair. Demander toujours

unsurveillant dment form de se tenir proximit. Des fumes et des

gaz de soudage peuvent dplacer lair et abaisser le niveau doxy-gne provoquant des blessures ou des accidents mortels. Sassu-rer que lair de respiration ne prsente aucun danger.

D Ne pas souder dans des endroits situs proximit doprations dedgraissage, de nettoyage ou de pulvrisation. La chaleur et lesrayons de larc peuvent ragir en prsence de vapeurs et former desgaz hautement toxiques et irritants.

D Ne pas souder des mtaux munis dun revtement, tels que laciergalvanis, plaqu en plomb ou au cadmium moins que le revte-ment nait t enlev dans la zone de soudure, que lendroit soit bienventil, et si ncessaire, en portant un respirateur alimentationdair. Les revtements et tous les mtaux renfermant ces lmentspeuvent dgager des fumes toxiques en cas de soudage.

LES FUMES ET LES GAZ peuventtre dangereux.


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OM-293 Page 6

Le rayonnement de larc du procd de soudagegnre des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provoquer

des brlures dans les yeux et sur la peau. Des tincelles sont projetespendant le soudage.

LES RAYONS DE LARC peuvent pro-voquer des brlures dans les yeux etsur la peau.

D Porter un casque de soudage muni dun cran de filtre appropri pourprotger votre visage et vos yeux pendant le soudage ou pour regar-der (voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit).

D Porter des protections approuvs pour les oreilles si le niveau sondre esttrop lev.

D Utiliser des crans ou des barrires pour protger des tiers de lclairet de lblouissement; demander aux autres personnes de ne pas re-garder larc.

D Porter des vtements de protection constitu dans une matire dura-ble, rsistant au feu (cuir ou laine) et une protection des pieds.

Le soudage effectu sur des conteneurs ferms telsque des rservoirs, tambours ou des conduites peutprovoquer leur clatement. Des tincelles peuvent treprojetes de larc de soudure. La projection dtincel-

les, des pices chaudes et des quipements chauds peut provoquer desincendies et des brlures. Le contact accidentel de llectrode avec desobjets mtalliques peut provoquer des tincelles, une explosion, unsurchauffement ou un incendie. Avant de commencer le soudage, vrifieret sassurer que lendroit ne prsente pas de danger.

LE SOUDAGE peut provoquer unincendie ou une explosion.

D Se protger et dautres personnes de la projection dtincelles et demtal chaud.

D Ne pas souder dans un endroit l o des tincelles peuvent tomber surdes substances inflammables.

D Dplacer toutes les substances inflammables une distance de 10,7m de larc de soudage. En cas dimpossibilit les recouvrir soigneuse-ment avec des protections homologus.

D Des tincelles et des matriaux chauds du soudage peuvent facile-ment passer dans dautres zones en traversant de petites fissures etdes ouvertures.

D Surveiller tout dclenchement dincendie et tenir un extincteur proxi-mit.

D Le soudage effectu sur un plafond, plancher, paroi ou sparationpeut dclencher un incendie de lautre ct.

D Ne pas effectuer le soudage sur des conteneurs ferms tels que desrservoirs, tambours, ou conduites, moins quils naient t prpa-rs correctement conformment AWS F4.1 (voir les normes de

scurit).D Brancher le cble sur la pice le plus prs possible de la zone de sou-dage pour viter le transport du courant sur une longue distance pardes chemins inconnus ventuels en provoquant des risques dlec-trocution et dincendie.

D Ne pas utiliser le poste de soudage pour dgeler des conduites ge-les.

D En cas de non utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.

D Porter des vtements de protection dpourvus dhuile tels que desgants en cuir, une chemise en matriau lourd, des pantalons sans re-vers, des chaussures hautes et un couvre chef.

D Avant de souder, retirer toute substance combustible de vos pochestelles quun allumeur au butane ou des allumettes.

DES PARTICULES VOLANTESpeuvent blesser les yeux.

D Le soudage, lcaillement, le passage de la pice la brosse en fil de fer, et le meulage gnrentdes tincelles et des particules mtalliques vo-

lantes. Pendant la priode de refroidissement des soudures, elles ris-quent de projeter du laitier.

D Porter des lunettes de scurit avec crans latraux ou un cran facial.

LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumme la mort.

D Fermer lalimentation du gaz protecteur en cas denon utilisation.

D Veiller toujours bien arer les espaces confins ou se servir dun respi-rateur dadduction dair homologu.

DES PICES CHAUDES peuvent pro-voquer des brlures graves.

D Ne pas toucher des parties chaudes mains nuesD Prvoir une priode de refroidissement avant

dutiliser le pistolet ou la torche.

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez distance.

D Les porteurs dun stimulateur cardiaque doiventdabord consulter leur mdecin avant de sapprocherdes oprations de soudage larc, de gougeage oude soudage par points.

LE BRUIT peut affecter loue.

Le bruit des processus et des quipements peut affecterloue.

D Porter des protections approuvs pour les oreilles sile niveau sondre est trop lev.

Des bouteilles de gaz protecteur contiennent du gazsous haute pression. Si une bouteille est endomma-ge, elle peut exploser. Du fait que les bouteilles de gazfont normalement partie du procd de soudage, les

manipuler avec prcaution.D Protger les bouteilles de gaz comprim dune chaleur excessive,

des chocs mcaniques, du laitier, des flammes ouvertes, des tin-celles et des arcs.

D Placer les bouteilles debout en les fixant dans un support stationnai-re ou dans un porte-bouteilles pour les empcher de tomber ou dese renverser.

D Tenir les bouteilles loignes des circuits de soudage ou autres cir-cuits lectriques.

D Ne jamais placer une torche de soudage sur une bouteille gaz.D Une lectrode de soudage ne doit jamais entrer en contact avec une

bouteille.

D Ne jamais souder une bouteille pressurise risque dexplosion.D Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,

tuyaux et raccords convenables pour cette application spcifique;les maintenir ainsi que les lments associs en bon tat.

D Ne pas tenir la tte en face de la sortie en ouvrant la soupape de la

bouteille.D Maintenir le chapeau de protection sur la soupape, sauf en cas duti-

lisation ou de branchement de la bouteille.

D Lire et suivre les instructions concernant les bouteilles de gaz com-prim, les quipements associs et les publications P-1 CGA nu-mres dans les normes de scurit.

Si des BOUTEILLES sont endomma-ges, elles pourront exploser.


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OM-293 Page 7

1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnementet la maintenance

Risque DINCENDIE OUDEXPLOSION.

D Ne pas placer lappareil sur, au-dessus ou proxi-mit de surfaces infllammables.

D Ne pas installer lappareil proximit de produits inflammables

D Ne pas surcharger linstallation lectrique sassurer que lalimen-tation est correctement dimensionn et protg avant de mettrelappareil en service.

LA CHUTE DE LAPPAREIL peutblesser.

D Utiliser lanneau de levage uniquement pour sou-lever lappareil, NON PAS les chariot, les bouteil-les de gaz ou tout autre accessoire.

D Utiliser un engin dune capacit approprie poursoulever lappareil.

D En utilisant des fourches de levage pour dplacer lunit, sassurerque les fourches sont suffisamment longues pour dpasser du ctoppos de lappareil.

LEMPLOI EXCESSIF peutSURCHAUFFER LQUIPEMENT.

D Prvoir une priode de refroidissement, respec-ter le cycle opratoire nominal.

D Rduire le courant ou le cycle opratoire avant derecommancer le soudage.

D Ne pas obstruer les passages dair du poste.

LES CHARGES LECTROSTATI-QUES peuvent endommager lescircuits imprims.

D tablir la connexion avec la barrette de terreavant de manipuler des cartes ou des pices.

D Utiliser des pochettes et des botes antistatiquespour stocker, dplacer ou expdier des cartes decircuits imprimes.

DES ORGANES MOBILES peuventprovoquer des blessures.

D Ne pas sapprocher des organes mobiles.D Ne pas sapprocher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuventprovoquer des blessures.

D Ne pas appuyer sur la gachette avant den avoir

reu linstruction.D Ne pas diriger le pistolet vers soi, dautres person-nes ou toute pice mcanique en engageant le filde soudage.

DES ORGANES MOBILES peuventprovoquer des blessures.

D Rester lcart des organes mobiles comme leventilateur.

D Maintenir ferms et fixement en place les portes,panneaux, recouvrements et dispositifs de

protection.

LE RAYONNEMENT HAUTE FR-QUENCE (H.F.) risque de provoquerdes interfrences.

D Le rayonnement haute frequence peut provoquerdes interfrences avec les quipements de ra-dionavigation et de communication, les servicesde scurit et les ordinateurs.

D Demander seulement des personnes qualifies familiarisesavec des quipements lectroniques de faire fonctionner linstalla-tion.

D Lutilisateur est tenu de faire corriger rapidement par un lectricienqualifi les interfrences rsultant de linstallation.

D Si le FCC signale des interfrences, arrter immdiatement lappa-reil.

D Effectuer rgulirement le contrle et lentretien de linstallation.D Maintenir soigneusement ferms les portes et les panneaux des

sources de haute frquence, maintenir les clateurs une distancecorrecte et utiliser une terre et et un blindage pour rduire les interf-rences ventuelles.

LE SOUDAGE LARC risque deprovoquer des interfrences.

D Lnergie lectromagntique risque de provoquerdes interfrences pour lquipement lectroniquesensible tel que les ordinateurs et lquipementcommand par ordinateur tel que les robots.

D Veiller ce que tout lquipement de la zone de soudage soit com-patible lectromagntiquement.

D Pour rduire la possibilit dinterfrence, maintenir les cbles desoudage aussi courts que possible, les grouper, et les poser aussibas que possible (ex. par terre).

D Veiller souder une distance de 100 mtres de tout quipementlectronique sensible.

D Veiller ce que ce poste de soudage soit pos et mis la terreconformment ce mode demploi.

D En cas dinterfrences aprs avoir pris les mesures prcdentes, ilincombe lutilisateur de prendre des mesures supplmentaires tel-les que le dplacement du poste, lutilisation de cbles blinds, luti-lisation de filtres de ligne ou la pose de protecteurs dans la zone detravail.

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez dis-tance.

D Les porteurs dun stimulateur cardiaque doiventdabord consulter leur mdecin avant de sappro-cher des oprations de soudage larc, de gou-geage ou de soudage par points.


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OM-293 Page 8

1-4. Principales normes de scurit

Safety in Welding and Cutting, norme ANSI Z49.1, de lAmerican Wel-ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendentof Documents, U.S. Government Printing Office, Washington, D.C.20402.

Recommended Safe Practice for the Preparation for Welding and Cut-ting of Containers That Have Held Hazardous Substances, norme AWSF4.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL33126

National Electrical Code, NFPA Standard 70, de la National Fire Protec-tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,de la Compressed Gas Association, 1235 Jefferson Davis Highway,Suite 501, Arlington, VA 22202.

Rgles de scuriten soudage, coupage et procds connexes, normeCSA W117.2, de lAssociation canadienne de normalisation, vente denormes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-tion, norme ANSI Z87.1, de lAmerican National Standards Institute,1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme NFPA 51B, de la National FireProtection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs lectromagntiques

Donnes sur le soudage lectrique et sur les effets, pour lorganisme,des champs magntiques basse frquence

Le courant de soudage, pendant son passage dans les cbles de sou-dage, causera des champs lectromagntiques. Il y a eu et il y a encoreun certain souci propos de tels champs. Cependant, aprs avoir ex-amin plus de 500 tudes qui ont t faites pendant une priode derecherche de 17 ans, un comit spcial ruban bleu du National Re-

search Council a conclu: Laccumulation de preuves, suivant lejugement du comit, na pas dmontr que lexposition aux champsmagntiques et champs lectriques haute frquence reprsente unrisque la sant humaine. Toutefois, des tudes sont toujours en courset les preuves continuent tre examines. En attendant que les con-clusions finales de la recherche soient tablies, il vous seraitsouhaitable de rduire votre exposition aux champs lectromagnti-ques pendant le soudage ou le coupage.

Afin de rduire les champs lectromagntiques dans lenvironnementde travail, respecter les consignes suivantes :

1 Garder les cbles ensembles en les torsadant ou en lesattachant avec du ruban adhsif.

2 Mettre tous les cbles du ct oppos de loprateur.

3 Ne pas courber pas et ne pas entourer pas les cbles autour devotre corps.

4 Garder le poste de soudage et les cbles le plus loin possible devous.

5 Relier la pince de masse le plus prs possible de la zone desoudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant toutconsulter leur docteur. Si vous tes dclar apte par votre docteur, il estalors recommand de respecter les consignes cidessus.


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SECTION 2 INSTALLATION

2-1. Specifications

Rated Welding Voltage Range Maximum Open-Amperes Input at Rated LoadOutput, 60 Hz, Single-Phase

Output DC Circuit Voltage DC200 V 230 V 460 V KVA KW

200 A @ 28 Volts DC,60% Duty Cycle

Low Range: 1020V; High Range:

2030 V42

46(1.2*)

40(1.0*)

20(0.5*)

9.2(0.2*)

8.3(0.1*)

*While idling

2-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.

If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orvoltage, or duty cycle beforewelding.

Y Exceeding duty cycle candamage unit and void war-ranty.

Overheating

0

15

A or V

ORReduce Duty CycleMinutes

sduty1 5/95 / 155 647-A

60% Duty Cycle At 200 Amperes

6 Minutes Welding 4 Minutes Resting


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2-3. Volt-Ampere Curves

va_curve1 4/95 049 424-E

Volt-ampere curves show mini-mum and maximum voltage andamperage output capabilities ofunit. Curves of other settings fall be-tween curves shown.

2-4. Selecting A Location

1 Lifting Forks

Use lifting forks to move unit.

Extend forks beyond opposite sideof unit.

2 Rating Label

Use rating label to determine inputpower needs.

3 Line Disconnect Device

Locate unit near correct input pow-er supply.

Y Special installation may berequired where gasoline orvolatile liquids are present see NEC Article 511 or CECSection 20.

1

Movement

Location And Airflow

800 402 / Ref. 121 471-H

2

18 in

3

(460 mm)

18 in

(460 mm)

Tools Needed:

3/8 in


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2-5. Dimensions And Weights

Dimensions

Height 23-1/4 in (591 mm)

CH 8 Holes Width 16 in (406 mm)

Depth 22-3/4 in (578 mm)

A 13 in (330 mm)

A B 12-1/4 in (311 mm)

BC 3/4 in (19 mm)

Front D 16-1/16 in (408 mm)

E 14-29/32 in (379 mm)

F 15-13/32 in (137 mm)

G G 13/32 in (10 mm)

EF

H 7/16 (11 mm) Dia

155 897-ADWeight

168 lb (76 kg)

2-6. Weld Output Terminals And Selecting Cable Sizes

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less150 ft(45 m)

200 ft(60 m)

250 ft(70 m)

300 ft(90 m)

350 ft(105 m)

400 ft(120 m)

Weld OutputTerminals

WeldingAmperes

10 60%DutyCycle

60 100%DutyCycle

10 100% Duty Cycle

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

Negative()

Positive(+) 250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

Ref. 121 470-E300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D


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2-7. Remote 14 Receptacle Information

A JK I

Socket* Socket Information

BK I

C L N H

D M G 24 VOLTS AC

A 24 volts ac. Protected by circuit breaker CB2.

E F24 VOLTS AC

B Contact closure to A completes 24 volts ac con-

tactor control circuit.

115 VOLTS AC

I 115 volts ac. Protected by circuit breaker CB1.

115 VOLTS AC

J Contact closure to I completes 115 volts ac con-tactor control circuit.

G Circuit common for 24 and 115 volts ac circuits.

Ref. 121 470-E / Ref. 192 412

GNDK Chassis common.

*The remaining sockets are not used.

2-8. Electrical Service Guide

Input Voltage 200 230 460

Input Amperes At Rated Output 46 40 20

Max Recommended Standard Fuse Rating In Amperes 1

Time-Delay 2 50 50 25

Normal Operating 3 70 60 30

Min Input Conductor Size In AWG/Kcmil 8 8 12

Max Recommended Input Conductor Length In Feet (Meters)89

(27)118(36)

188(57)

Min Grounding Conductor Size In AWG/Kcmil 8 10 12

Reference: 1999 National Electrical Code (NEC)

1 Consult factory for circuit breaker applications.

2 Time-Delay fuses are UL class RK5 .3 Normal Operating (general purpose no intentional delay) fuses are UL class K5 (up to and including 60 amp), and UL class H ( 65 amp and

above).


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2-9. Placing Jumper Links And Connecting Input Power

S-0279-B / Ref. 121 471-H

Check input voltage available atsite.

1 Jumper Link Label

2 Jumper Link

Move jumper links to match inputpower.

3 Line Disconnect Device

Select type and size of overcurrent

protection using Section 2-8. Rat-ings must comply with applicablecodes. Install conductors in conduitor equivalent into a deenergizedline disconnect device.

Reinstall wrapper.

Y Special installation may berequired where gasoline orvolatile liquids are present see NEC Article 511 or CECSection 20.

Tools Needed:

L1

GND/PEEarth Ground

L2

1

2

3/8 in

S-153 408-A

200V 230V 460V

3


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SECTION 3 OPERATION

3-1. Controls

1 Voltage Range Switch

Use switch to select voltage range.

2 Voltage Adjustment Switch

Use switch to adjust voltage within range se-lected by Voltage Range switch. Each posi-tion of the switch is a change of 2 volts.

Y Do not change position of VoltageRange switch or Voltage Adjustmentswitch while welding. Arcing can da-mage contacts, causing connectionsto fail.

3 Power Switch

4 Pilot Light

5 Circuit Breaker CB2

If CB2 opens, the 24 volts ac output to the Re-mote 14 receptacle stops.

6 Circuit Breaker CB1

If CB1 opens, the 115 volts ac output to theRemote 14 receptacle stops.

Press button to reset circuit breakers.

1

3

2

Ref. 121 471-H / Ref. 192 412

6

5

4


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SECTION 4 MAINTENANCE & TROUBLESHOOTING

4-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

ReplaceUnreadable

Labels

Repair OrReplaceCracked

WeldCable

ReplaceCracked

Parts14-Pin Cord

Torch, Electrode Holder,Or Gun Cable

Clean AndTightenWeld

Terminals

6 Months

Blow OutOr

VacuumInside

During HeavyService,

Clean MonthlyOR

4-2. Troubleshooting

Trouble Remedy

No weld output; unit completely inoperative; pilot lightnot on.

Place Power switch in the On position (see Section 3-1).

Place line disconnect switch in the On position (see Section 2-9).

Check line fuse(s); replace if open or reset circuit breaker(s) (see Section 2-9).

Check for proper input connections (see Section 2-9).

Erratic weld output. Use proper size and type weld cable (see Section 2-6).

Clean and tighten all weld connections (see Section 4-1).

Check for proper input connections (see Section 2-9).

No open-circuit voltage; pilot light on; wire does notfeed.

Secure gun trigger connections or see gun Owners Manual.

Secure plug in Remote 14 receptacle RC3 (see Section 2-7).

No open-circuit voltage; pilot light on; wire feeds. Thermostat open (overheating). Allow unit to cool.

Have Factory Authorized Service Agent check contactor W.

Open-circuit voltage normal; pilot light on; wire doesnot feed.

Check gun or wire feeder Owners Manual.

No 115 volts ac output at Remote 14 receptacle RC3. Reset circuit breaker CB1 (see Section 3-1).

No 24 volts ac output at Remote 14 receptacle RC3. Reset circuit breaker CB2 (see Section 3-1).


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SECTION 5 ELECTRICAL DIAGRAM

192 974

Figure 5-1. Circuit Diagram For Welding Power Source


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OM-293 Page 17

SECTION 6 PARTS LIST

121 583-H

. Hardware is common andnot available unless listed.

1

2

3

45

6

7 (Fig 63)

8

(Fig 62)19

20

9

10

111213

1415

16

1718

Figure 6-1. Main Assembly

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 6-1. Main Assembly

Quantity

1 +047 167 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 134 327 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 038 620 LINK, jumper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 TE1 038 779 BLOCK, term 30A 5P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 196 253 STRIP, mtg term block 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Z 192 984 STABILIZER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

022 391 STRIP, polyest gl lam .062 x 1.500 x 3.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Fig 6-3 PANEL, rear w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 071 906 CORD SET, 8-10ga 3/c 8ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 081 586 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 TP1 123 317 THERMOSTAT, NO 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 T1 191 540 TRANSFORMER, pwr main 200/230/460 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 789 CAPACITOR ASSY (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 192 727 BRACKET, mtg capacitors 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 190 790 STRIP, mtg center capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 190 793 STRIP, insulator capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 C7 184 584 CAPACITOR, elctlt 15000uf 45VDC 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 190 791 STRIP, mtg outside capacitor 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 190 792 BUS BAR, capacitor assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 083 147 GROMMET, scr no. 8/10 panel hole 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Fig 6-2 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 +049 150 PANEL, side 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109 035 LABEL, warning electric shock can kill 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.


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OM-293 Page 18


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OM-293 Page 19

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 6-2. Panel, Front w/Components (Fig 6-1 Item 19)

Quantity

1 206 444 LABEL, nameplate 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 192 973 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 S2 171 610 SWITCH, selector 2 position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 S1 128 755 SWITCH, tgl DPST 40A 600VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 S3 153 197 SWITCH, selector 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 CB2 083 432 CIRCUIT BREAKER, man reset 1P 10A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 CB1 083 431 CIRCUIT BREAKER, man reset 1P 5A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 RC3 143 976 CONNECTOR w/SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

079 534 CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 734 CONNECTOR, circ 14 pin plug Amp 213571-2. . . . . . . . . . . . . . . . . . . . . . .134 731 CONNECTOR, circ pin push-in 14-18ga Amp 213603-1. . . . . . . . . . . . . . . . . . . . . . .079 739 CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 (or). . . . . . . . . . . . . . . . . . . . . . .143 922 CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3. . . . . . . . . . . . . . . . . . . . . . .

9 039 046 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 180 732 BOOT, negative output stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 735 WASHER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181 169 SPACER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 148 956 HANDLE, switch range, selector 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 343 SCREW, K50 x 20 soc hd 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 179 848 BOOT, positive output stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 039 047 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 PL1 163 562 LIGHT, white 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 186 058 COVER, dust 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



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OM-293 Page 20

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 6-3. Panel, Rear w/Components (Fig 6-1 Item 7)

Quantity

1 081 372 BLADE, fan 9 in 5wg 20deg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 172 529 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 R2 079 781 RESISTOR, WW fxd 25W 50 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 604 102 CONNECTOR, clamp cable 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 W 195 568 CONTACTOR, 60A 3P 120VAC (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 114 786 LINK, connecting contactor term 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 CR1 006 393 RELAY, encl 24VAC DPDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 SR3 192 976 RECTIFIER/WIND TUNNEL, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 TP2 193 248 THERMOSTAT, NO 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 TP3 193 247 THERMOSTAT, NC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 192 994 RECTIFIER, SI 1Ph 300A 600PIV (top and bottom units) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 192 975 BRACKET, mtg rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 FM 081 373 MOTOR, 1/15hp 115VAC 60Hz 3000RPM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 137 912 BRACKET, mtg fan motor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 192 982 BUS BAR, rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Warranty Questions?

Call1-800-4-A-MILLERfor your localMiller distributor.

miller_warr 7/00

Your distributor also givesyou ...

ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours.

SupportNeed fast answers to thetough welding questions?Contact your distributor.The expertise of thedistributor and Miller isthere to help you, everystep of the way.

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.

LIMITED WARRANTY Subject to the terms and conditionsbelow, Miller Electric Mfg. Co., Appleton, Wisconsin, warrantsto its original retail purchaser that new Miller equipment soldafter the effective date of this limited warranty is free of defectsin material and workmanship at the time it is shipped by Miller.THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHERWARRANTIES, EXPRESS OR IMPLIED, INCLUDING THEWARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair orreplace any warranted parts or components that fail due tosuch defects in material or workmanship. Miller must benotified in writing within thirty (30) days of such defect orfailure, at which time Miller will provide instructions on thewarranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipmentlisted below in the event of such a failure within the warrantytime periods. All warranty time periods start on the date thatthe equipment was delivered to the original retail purchaser, or

one year after the equipment is sent to a North Americandistributor or eighteen months after the equipment is sent to anInternational distributor.

1. 5 Years Parts 3 Years Labor

* Original main power rectifiers

* Inverters (input and output rectifiers only)

2. 3 Years Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Supplies

* Intellitig

* Engine Driven Welding Generators(NOTE: Engines are warranted separately bythe engine manufacturer.)

3. 1 Year Parts and Labor

* DS-2 Wire Feeder

* Motor Driven Guns (w/exception of Spoolmate185 & Spoolmate 250)

* Process Controllers

* Positioners and Controllers

* Automatic Motion Devices

* RFCS Foot Controls

* Induction Heating Power Sources

* Water Coolant Systems

* HF Units

* Grids

* Maxstar 140

* Spot Welders

* Load Banks* Miller Cyclomatic Equipment

* Running Gear/Trailers

* Plasma Cutting Torches (except APT & SAFModels)

* Field Options(NOTE: Field options are covered under TrueBlue for the remaining warranty period of theproduct they are installed in, or for a minimum ofone year whichever is greater.)

4. 6 Months Batteries

5. 90 Days Parts

* MIG Guns/TIG Torches

* Induction Heating Coils and Blankets

* APT, ZIPCUT & PLAZCUT Model Plasma CuttingTorches

* Remote Controls

* Accessory Kits

* Replacement Parts (No labor)

* Spoolmate 185 & Spoolmate 250

* Canvas Covers

Millers True Blue Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,cutting nozzles, contactors, brushes, slip rings,relays or parts that fail due to normal wear.

2. Items furnished by Miller, but manufactured by others,such as engines or trade accessories. These items arecovered by the manufacturers warranty, if any.

3. Equipment that has been modified by any party otherthan Miller, or equipment that has been improperlyinstalled, improperly operated or misused based uponindustry standards, or equipment which has not hadreasonable and necessary maintenance, or equipmentwhich has been used for operation outside of thespecifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASEAND USE BY COMMERCIAL/INDUSTRIAL USERS ANDPERSONS TRAINED AND EXPERIENCED IN THE USEAND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, theexclusive remedies shall be, at Millers option: (1) repair; or (2)replacement; or, where authorized in writing by Miller inappropriate cases, (3) the reasonable cost of repair orreplacement at an authorized Miller service station; or (4)payment of or credit for the purchase price (less reasonabledepreciation based upon actual use) upon return of the goodsat customers risk and expense. Miller s option of repair orreplacement will be F.O.B., Factory at Appleton, Wisconsin, orF.O.B. at a Miller authorized service facility as determined byMiller. Therefore no compensation or reimbursement fortransportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIESPROVIDED HEREIN ARE THE SOLE AND EXCLUSIVEREMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FORDIRECT, INDIRECT, SPECIAL, INCIDENTAL ORCONSEQUENTIAL DAMAGES (INCLUDING LOSS OFPROFIT), WHETHER BASED ON CONTRACT, TORT ORANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREINAND ANY IMPLIED WARRANTY, GUARANTY ORREPRESENTATION AS TO PERFORMANCE, AND ANYREMEDY FOR BREACH OF CONTRACT TORT OR ANYOTHER LEGAL THEORY WHICH, BUT FOR THISPROVISION, MIGHT ARISE BY IMPLICATION,OPERATION OF LAW, CUSTOM OF TRADE OR COURSE

OF DEALING, INCLUDING ANY IMPLIED WARRANTY OFMERCHANTABILITY OR FITNESS FOR PARTICULARPURPOSE, WITH RESPECT TO ANY AND ALLEQUIPMENT FURNISHED BY MILLER IS EXCLUDED ANDDISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how longan implied warranty lasts, or the exclusion of incidental,indirect, special or consequential damages, so the abovelimitation or exclusion may not apply to you. This warrantyprovides specific legal rights, and other rights may beavailable, but may vary from state to state.

In Canada, legislation in some provinces provides for certainadditional warranties or remedies other than as stated herein,and to the extent that they may not be waived, the limitationsand exclusions set out above may not apply. This LimitedWarranty provides specific legal rights, and other rights maybe available, but may vary from province to province.


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Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA

International HeadquartersUSAUSA Phone: 920-735-4505 Auto-AttenUSA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters United KingdomPhone: 44 (0) 1204-593493FAX: 44 (0) 1204-598066

www.MillerWelds.com

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Always provide Model Name and Serial/Style Number.

Call 1-800-4-A-Miller or see our website at www.MillerWelds.comto locate a DISTRIBUTOR or SERVICE AGENCY near you.

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Informationand Parts)

Circuit Diagrams

Welding Process Handbooks

Contact the Delivering Carrier for:

For assistance in filing or settling claims,contact your distributor and/or equipmentmanufacturers Transportation Department

For Service

Owners Record

File a claim for loss or damage duringshipment.

Contact your Distributor for:

Miller Regeny 250

Documents

Transcript of Miller Regeny 250