Miller REGENCY 250 Owner's Manual
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Miller REGENCY 250 Owner's Manual

Miller REGENCY 250 Owner's Manual

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See also: Owner's Manual
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
cover 5/94 − ST-121 471-D
OWNER'S
MANUAL
Regency® 250
Constant Voltage DC Arc Welding Power Source
For GMAW Welding
200 Amperes, 28 Volts DC At 60% Duty Cycle
Uses Single-Phase Input Power
Fan-On-Demand And Receptacle Overload Protection
14-Pin Remote Control Receptacle
For Options And Accessories, See Rear Cover
©
1995 MILLER Electric Mfg. Co.
February 1995
Form: OM-293F
Effective With Serial No. KF785422
Give this manual to the operator.
For help, call your distributor
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912
414-734-9821
PRINTED IN USA

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Summary of Contents for Miller REGENCY 250

  • Page 1 Have only trained and qualified persons For help, call your distributor install, operate, or service this unit. Call your distributor if you do not understand or: MILLER Electric Mfg. Co., P.O. Box 1079, the directions. Appleton, WI 54912 414-734-9821 ©...

  • Page 2: Limited Warranty

    (Equipment with a serial number preface of “KD” 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 conditions below, MILLER Elec- 6 Months —...

  • Page 3: Table Of Contents

    EMF INFORMATION NOTE Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of To reduce magnetic fields in the workplace, use the following procedures: the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric &...

  • Page 4: Section 1 − Safety Information

    SECTION 1 − SAFETY INFORMATION mod1.1 2/93 Read all safety messages throughout this manual. Obey all safety messages to avoid injury. Learn the meaning of WARNING and CAUTION. Safety Alert Symbol Signal Word WARNING means possible death or serious injury can happen. WARNING CAUTION CAUTION means possible minor...

  • Page 5: Volt-Ampere Curves

    2-1. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. ssb1.1 10/91 − ST-049 424-D Figure 2-1. Volt-Ampere Curves 2-2. Duty Cycle CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage unit and void warranty.

  • Page 6: Selecting A Location And Moving Welding Power Source

    3-2. Selecting A Location And Moving Welding Power Source WARNING ELECTRIC SHOCK can kill. FUMES can be hazardous; LACK OF • F RESH AI R AND PRO PER VEN- Do not touch live electrical parts. TILATION can be harmful. • Disconnect input power conductors from de- •...

  • Page 7: Selecting And Preparing Weld Output Cables

    NOTE Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc. Inches Millimeters 23-1/4 22-3/4 12-1/4 16-1/16 14-29/32 5-13/32 Front 13/32 7/16 Dia. 11 Dia. 6 Holes 6 Holes ST-155 897-A Figure 3-3. Overall Dimensions And Base Mounting Hole Layout 3-3.
  • Page 8 Table 3-1. Weld Cable Size* Total Cable (Copper) Length In Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) Or Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m) Welding...

  • Page 9: Connecting To Weld Output Receptacles

    3-4. Connecting To Weld Output Receptacles WARNING ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical equipment. • Do not touch live electrical parts. • Turn Off welding power source before making any weld output connections. • Do not change position of welding cable connectors while welding. •...

  • Page 10: Connecting Input Power

    Table 3-2. Remote 14 Socket Information Socket* Socket Information 24 volts ac. Protected by circuit breaker CB2. Contact closure to A completes 24 volts ac contactor control circuit. 115 volts ac. Protected by circuit breaker CB1. Contact closure to I completes 115 volts ac contactor control circuit. Circuit common for 24 and 115 volts ac circuits.
  • Page 11 B. Connecting Input Power Have only qualified persons make this installation. Line Disconnect Device Of Proper Rating Grounding Conductor − Green Or Green With Yellow Stripe(s) Input Conductors Install grounding conductor and input conductors from unit to deenergized line disconnect device.

  • Page 12: Section 4 − Operation

    SECTION 4 − OPERATION WARNING ELECTRIC SHOCK can kill. ARC RAYS can burn eyes and skin; • NOISE can damage hearing. Always wear dry insulating gloves. • • Wear welding helmet with correct shade of filter. Insulate yourself from work and ground. •...
  • Page 13 Work Clamp Connect work clamp to a clean, paint-free location on workpiece, as Tools Needed: close to weld area as possible. Use wire brush or sandpaper to clean metal at weld joint area. Use chipping hammer to remove slag after welding. sb4.1 2/93 Figure 4-3.
  • Page 14 CAUTION ARCING can damage switch. • Do not change Voltage Adjustment switch position while welding. Arcing inside switch can damage contacts, causing switch to fail. warn5.1 2/93 Voltage Adjustment Switch Use switch to adjust open-circuit voltage within range selected by Voltage Range selector plug.

  • Page 15: Section 5 − Maintenance & Troubleshooting

    Install & Install & Prepare Put On Turn On Turn On Feeder Connect Wire Feeding Personal Safety Set Controls Shielding Gas And Welding Equipment System Equipment Power Source Begin Welding ssb6.1 9/92 Figure 4-7. Sequence Of Gas Metal Arc Welding (GMAW) SECTION 5 −...

  • Page 16: Overload Protection

    5-2. Overload Protection READ SAFETY BLOCKS at start of WARNING Section 5 before proceeding. A. Overheating minutes When overheated, cooling fan begins Let fan run for Start welding. to run, and output may stop. 15 minutes. ssb10.1 1/94 − ST-121 471-D Figure 5-2.

  • Page 17: Troubleshooting

    5-3. Troubleshooting WARNING ELECTRIC SHOCK can kill. MOVING PARTS can cause injury. • • Do not touch live electrical parts. Keep away from moving parts. • Turn Off welding power source, and disconnect input power before inspecting, maintaining, or servicing. HOT PARTS can cause severe burns.

  • Page 18: Section 6 − Electrical Diagrams

    SECTION 6 − ELECTRICAL DIAGRAMS SB-119 335 Figure 6-1. Circuit Diagram For Welding Power Source OM-293 Page 15...
  • Page 19 SC-121 384-B Figure 6-2. Wiring Diagram For Welding Power Source OM-293 Page 16...

  • Page 20: Section 7 − Parts List

    SECTION 7 − PARTS LIST Fig 7-4 Fig 7-2 ST-121 583-C Figure 7-1. Main Assembly Item Dia. Part Mkgs. Description Quantity Figure 7-1. Main Assembly ....+047 167 WRAPPER .
  • Page 21 Fig 7-3 ST-121 587-A Figure 7-2. Panel, Front w/Components OM-293 Page 18...
  • Page 22 Item Dia. Part Mkgs. Description Quantity Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 20) ....057 608 RECEPTACLE, jack plug yellow (consisting of) .
  • Page 23 Item Part Description Quantity Figure 7-3. Switch, Selector (Fig 7-2 Item 6) ..005 562 BRACKET, mtg switch ............
  • Page 24 Item Dia. Part Mkgs. Description Quantity Figure 7-4. Panel, Rear w/Components (Fig 7-1 Item 8) ....081 373 MOTOR, 1/15hp 115VAC 60Hz 3000RPM ......

  • Page 25: Options And Accessories

    OPTIONS AND ACCESSORIES NO. 9C RUNNING GEAR (#041 492) Includes wheels, towing handle, and cylinder rack. EXTENSION HOSE AND CABLE KITS (#132 228) 25 ft. (7.6 m) (#132 229) 50 ft. (15.2 m) Extends leads, etc. between Spoolmatic® 30A gun and power source.

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