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Summary of Contents for Miller DC 253 Stick
- Page 1 OM-194 416A April 2000 Effective with serial number: 253 - 151971 403 - 151972 Processes Stick (SMAW) Welding Description DC 253 Stick and DC 403 Stick Visit our website at www.MillerWelds.com...
- Page 2 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING ... . 1-1. Symbol Usage ..........1-2. - Page 4 Via Privata Iseo, 6/E Indirizzo Costruttore: 20098 San Giuliano Milanese, Italy Declares that this product: DC 253 Stick and Dichiara che il Prodotto: DC 403 Stick Conforms to the following Directives and Standards: È Conforme alle seguenti Direttive e Norme.
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Page 5: Section 1 - Safety Precautions For Arc Welding
SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING safety_stickom1 6/95 1-1. Symbol Usage Y Marks a special safety message. Means Warning! Watch Out! There are possible hazards with this 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. -
Page 6: Additional Installation, Operation, And Maintenance Hazards
1. Protect compressed gas cylinders from excessive heat, CYLINDERS can explode if damaged. mechanical shocks, slag, open flames, sparks, and arcs. Shielding gas cylinders contain gas under high 2. Keep cylinders away from any welding or other electrical circuits. pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding 3. -
Page 7: Section 2 - Installation
115 kg 35% Duty Cycle Dimensions: DC 253 Stick: Height: 535 mm; Width: 520 mm; Length: 1000 mm DC 403 Stick: Height: 710 mm; Width: 620 mm; Length: 1120 mm 2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. -
Page 8: Volt-Ampere Curves
2-3. Volt-Ampere Curves Volt-ampere curve shows mini- mum and maximum voltage and amperage output capabilities of Model 253 unit. Max. Min. 100 150 250 300 400 450 Model 403 100 150 250 300 400 450 2-4. Selecting A Location Rating Label Use rating label to determine input power needs. -
Page 9: Typical Connections
2-5. Typical Connections 30 60 100 Typical Stick (SMAW) Connections 1.6 2 2.5 4 5 2-6. Weld Output Terminals and Selecting Cable Sizes 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... -
Page 10: Electrical Service Guide
2-7. Electrical Service Guide Model DC 253 Stick DC 403 Stick Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Reference: 1997 National Electrical Code (NEC) S-0092-J 2-8. Connecting Input Power Check input voltage available at site. -
Page 11: Section 3 - Operation
SECTION 3 – OPERATION 3-1. Controls Welding Current Indicator Welding Current Control Positive Output Terminal Negative Output Terminal Pilot Light On/Off Switch 30 60 100 1.6 2 2.5 4 5 SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power Maintain more often before maintaining. -
Page 12: Troubleshooting
4-2. Troubleshooting Trouble Remedy No weld output; unit completely inop- Be sure Power switch is On (see Section 3-1). erative. Be sure line disconnect switch is On (see Section 2-8). Check line fuse(s) and replace if necessary (see Sections 2-8). Check for proper input power connections (see Sections 2-7 and/or 2-8). -
Page 13: Section 5 - Electrical Diagrams
SECTION 5 – ELECTRICAL DIAGRAMS 400/230V 50/60 Hz PRI. Board R/L1 U/T1 – S/L2 V/T2 T/L3 W/T3 400V 230V ZL/SF Figure 5-1. Circuit Diagram For DC 253 Stick OM-194 416 Page 9... - Page 14 NOTE: This circuit is effective with serial number 151 792 for units coded 029 016 180. 400/230V 50/60 Hz PRI. Board R/L1 U/T1 S/L2 V/T2 T/L3 W/T3 – 400V 230V ZM/SF Figure 5-2. Circuit Diagram for DC 403 Stick OM-194 416 Page 10...
- Page 15 NOTE: This circuit is effective with serial number 170 143 for units coded 029 016 182. – 400/230V 50/60 Hz PRI. Board R/L1 U/T1 S/L2 V/T2 T/L3 W/T3 230V 400V ZM/SF Figure 5-3. Circuit Diagram for DC 403 Stick OM-194 416 Page 11...
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Page 16: Section 6 - Parts List
SECTION 6 – PARTS LIST 13–14 Figure 6-1. DC 253 Stick Parts View OM-194 416 Page 12... - Page 17 Parts List For DC 253 Stick Model Qty. Item Ref. Code 156121009 ZL.0.0.6 156011019 UZ.0.0.14 156122027 ZL.0.0.4 SEC. COIL 057015088 ZL.1.2 PRI. COIL 057015087 ZL.1.1 058021111 ZL.1 PRI BOARD 756069030 ZL.0.0.10 556070015 VA.0.0.15 056059265 ZL.1.1.1 556019047 ZL.0.0.7 057029003 UZ.1.1 056020037 UZ.0.0.15 056072064 UZ.0.0.4...
- Page 18 13–14 Figure 6-2. DC 403 Parts View OM-194 416 Page 14...
- Page 19 Parts List For DC 403 Stick Model Parts List For DC 403 Stick Model Effective with serial number 151 972 Effective with serial number 170 143 for units coded 029 016 180 for units coded 029 016 182 Qty. Qty. Item Ref.
- Page 20 Notes...
- Page 21 Notes...
- Page 22 Notes...
- Page 23 Effective January 1, 2000 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 APT, ZIPCUT & PLAZCUT Model Plasma Cutting below, Miller Electric Mfg.
- Page 24 Phone: 414-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 European Headquarters – United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 Miller Europe Italy Phone: 39 (0) 2982901 PRINTED IN USA 2000 Miller Electric Mfg. Co. 1/00...
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