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OM-293 120 243N
October 2001
Processes
MIG (GMAW) Welding
Description
Arc Welding Power Source
Regency 250
Visit our website at
www.MillerWelds.com
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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 bu
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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 . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body. years of resea
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 – INSTALLATION 2-1. Specifications Amperes Input at Rated Load Rated Welding Voltage Range Maximum Open- Output, 60 Hz, Single-Phase Output DC Circuit Voltage DC 200 V 230 V 460 V KVA KW Low Range: 10–20 200 A @ 28 Volts DC, 46 40 20 9.2 8.3 V; High Range: 42 60% Duty Cycle (1.2*) (1.0*) (0.5*) (0.2*) (0.1*) 20–30 V *While idling 2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s
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2-3. Volt-Ampere Curves Volt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. va_curve1 4/95 – 049 424-E 2-4. Selecting A Location 1 Lifting Forks Use lifting forks to move unit. Extend forks beyond opposite side of unit. Movement 2 Rating Label Use rating label to determine input power needs. 3 Line Disconnect Device Locate unit near correct input pow- er supply. Special installation may be 1 requ
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2-5. Dimensions And Weights Dimensions Height 23-1/4 in (591 mm) C H 8 Holes Width 16 in (406 mm) Depth 22-3/4 in (578 mm) A 13 in (330 mm) B 12-1/4 in (311 mm) A B C 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 13/32 in (10 mm) G F H 7/16 (11 mm) Dia E D 155 897-A Weight 168 lb (76 kg) 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)
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2-7. Remote 14 Receptacle Information Socket* Socket Information AJ K K II B L A 24 volts ac. Protected by circuit breaker CB2. NH C D M G 24 VOL 24 VOLTS TS AC AC F E B Contact closure to A completes 24 volts ac con- tactor control circuit. I 115 volts ac. Protected by circuit breaker CB1. 1 115 VOL 15 VOLTS TS AC AC J Contact closure to I completes 115 volts ac con- tactor control circuit. G Circuit common for 24 and 115 volts ac circuits. GND K Chassis common. Ref. 121 470-E / Ref. 192 412 *T
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2-9. Placing Jumper Links And Connecting Input Power Check input voltage available at site. 1 Jumper Link Label 2 Jumper Link Move jumper links to match input power. 3 Line Disconnect Device Select type and size of overcurrent protection using Section 2-8. Rat- ings must comply with applicable 1 codes. Install conductors in conduit or equivalent into a deenergized line disconnect device. Reinstall wrapper. 200V 230V 460V Special installation may be required where gasoline or volatile liquids a
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SECTION 3 – OPERATION 3-1. Controls 3 4 2 5 1 6 Ref. 121 471-H / Ref. 192 412 1 Voltage Range Switch Do not change position of Voltage 5 Circuit Breaker CB2 Range switch or Voltage Adjustment If CB2 opens, the 24 volts ac output to the Re- Use switch to select voltage range. switch while welding. Arcing can da- mote 14 receptacle stops. mage contacts, causing connections 2 Voltage Adjustment Switch 6 Circuit Breaker CB1 to fail. If CB1 opens, the 115 volts ac output to the Use switch to adju
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SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Disconnect power before maintaining. 3 Months Repair Or Replace Replace Unreadable Cracked Labels Weld Cable Clean And Replace Tighten Cracked Weld Parts Terminals Torch, Electrode Holder, 14-Pin Cord Or Gun Cable 6 Months Blow Out During Heavy Or Service, Vacuum OR Clean Monthly Inside 4-2. Troubleshooting Trouble Remedy No weld output; unit completely inoperative; pilot light Place Power switch in the On position (see Section
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SECTION 5 – ELECTRICAL DIAGRAM 192 974 Figure 5-1. Circuit Diagram For Welding Power Source OM-293 Page 16
