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Miller Subarc DC 1250, Owner'S Manual

The Miller Subarc DC 1250 is a powerful welding machine perfect for heavy-duty industrial applications. To ensure proper usage and maintenance of this equipment, make sure to download the free Owner's Manual from manualshive.com. This comprehensive manual provides step-by-step instructions for optimal performance and safety. Get your manual today!

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OM-2223 Page 29

Description

Part

No.

Dia.

Mkgs.

Item

No.

8-1. Main Assembly

Quantity

1

+179 432

PANEL, side

2

. . . 

. . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

2

179 431

COVER, top

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

3

164 700

BAFFLE, air

2

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

4

162 816

CHANNEL, upright front

2

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5

191 285

GUSSET ASSY

2

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

6

162 820

BAR, mtg lift eye

2

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

7

177 279

GASKET, lift eye

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

8

162 830

LIFT EYE

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

604 536

SCREW, .312-18 x 1.750hexhd gr 5

2

. . . . . . . . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . 

9

134 201

STAND-OFF SUPPORT, pc card

4

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

10

162 821

BRACKET, mtg LEM

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

11

HD1

148 417

TRANSDUCER, current 1000A module

1

. . . 

. . . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . 

PLG14

130 204

HOUSING PLUG PINS & SKTS

1

. . . . . . . . . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

12

191 213

BUS BAR, stabilizer

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

13

Z1

190 954

STABILIZER

1

. . . 

. . . . . . . . 

. . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14

C21-23

099 518

CAPACITOR

3

. . . 

. . . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15

T2

159 042

TRANSFORMER, control 50VA 24V 230/460/575 (60Hz)

1

. . . 

. . . . . . . . 

. . . . . . . 

. . 

. . . . . . . 

15

T2

159 043

TRANSFORMER, control 50VA 24V 380/400/440 (50Hz)

1

. . . 

. . . . . . . . 

. . . . . . . 

. . 

. . . . . . . 

16

TE1

193 495

PRIMARY BOX, (includes)

1

. . . 

. . . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17

601 835

NUT, 10-32 brs

24

. . . 

. . . . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18

038 887

STUD, pri bd brs 10-32 x 1.375

24

. . . 

. . . . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

038 618

LINK, jumper term bd pri

8

. . . . . . . . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

010 913

WASHER, flat .218 ID brs

24

. . . . . . . . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

601 835

NUT, 10-32 brs

24

. . . . . . . . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19

159 034

HOLDER, fuse mintr

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20

F1

*156 065

FUSE, crtg .5A 600V time delay

1

. . . 

. . . . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21

Figure 8-4

PANEL, rear w/components

1

. . . 

. . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

22

193 676

TERMINAL ASSY, primary 3phase

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

23

CR4

♦

140 750

SWITCH, reed

1

. . . 

. . . . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

24

W

193 473

CONTACTOR, size 3-1/2 3P 24VAC

1

. . . 

. . . . . . . . 

. . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . 

25

217 136

LABEL, warning electric shock 

2

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

25

176 254

LABEL, general precautionary wordless,intl (CE models only) 

2

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . 

26

193 462

BRACKET, contactor mount (50 Hz Models Only)

2

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . 

26

193 462

BRACKET, contactor mount (60 Hz Models Only)

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . 

27

163 359

BASE

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

28

T1

218 414

TRANSFORMER, pwr main 230/460/575

1

. . . 

. . . . . . . . 

. . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . 

28

T1

218 415

TRANSFORMER, pwr main 380/400/440

1

. . . 

. . . . . . . . 

. . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . 

TP1,2

175 405

THERMOSTAT, NC (Included w/T1)

2

. . . . . . . . . . . . 

. . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . 

TP4,5

168 891

THERMOSTAT, NC (Included w/T1) (fan control circuit)

2

. . . . . . . . . . . . 

. . . . . . 

. . . . 

. . . . . . . 

PLG6

168 847

CONNECTOR & SOCKETS

1

. . . . . . . . . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

RC6

168 845

CONNECTOR & PINS

1

. . . . . . . . . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG13

218 413

HOUSING, plug pin/skt (service kit)

1

. . . . . . . . . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . 

RC13

218 408

HOUSING, plug pin/skt (service kit)

1

. . . . . . . . . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . 

31

161 294

BRACKET, mtg rectifier

2

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

32

Figure 8-2

PANEL, front w/components

1

. . . 

. . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

33

SR1

191 257

RECTIFIER, scr main (Figure 8-3)

1

. . . 

. . . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG7

152 249

CONNECTOR & PINS

1

. . . . . . . . . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

RC7

168 846

CONNECTOR & SOCKETS

1

. . . . . . . . . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

010 467

CONNECTOR, clamp cable 1.250

1

. . . . . . . . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

34

C1

221 959

CAPACITOR ASSEMBLY, (50 Hz Models Only) (includes)

1

. . . 

. . . . . . . . 

. . . . . . . 

. . 

. . . . . . 

163 535

CAPACITOR, elctlt 16000uf 60 VDC

6

. . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . 

162 817

Bus Bar, capacitor

2

. . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

R6

140 002

RESISTOR, ww fxd 10w 500 ohm

1

. . . . . . . . . . . . . . 

. . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . 

182 660

BRACKET, mtg capacitor 

2

. . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

36

207 805

CONTACTOR ASSEMBLY (50 Hz Models Only)

1

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . 

37

604 536

SCREW, .312-18 x 1.75 hex hd-pln gr5 pld

2

. . . 

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . 

♦

Part of Option 195 048 Ground Current Sensor.

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Summary of Contents for Subarc DC 1250

Page 1: ...Processes Description Multiprocess Welding Arc Welding Power Source OM 2223 190 969R January 2005 Dimension 1000 1250 Visit our website at www MillerWelds com...

Page 2: ...ue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the...

Page 3: ...Label 10 3 3 Electric Shock And Airflow Label 10 3 4 Nameplate Safety Symbols 10 3 5 Manufacturer s Rating Label For CE Products 11 3 6 Symbol Definitions 11 SECTION 4 INSTALLATION 12 4 1 Specificatio...

Page 4: ...ery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Safety Requirements for Arc Welding Equipment part 1 EN 60974 1 1990 Arc Welding Equipment Part 1 Welding Power Sources IEC 974 1 A...

Page 5: ...hat cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power c...

Page 6: ...lding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane light...

Page 7: ...ng a qualified electrician prompt ly correct any interference problem resulting from the installa tion D If notified by the FCC about interference stop using the equipmentat once D Have the installati...

Page 8: ...e 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Su...

Page 9: ...d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre D Pour ex cuter les branchements d entr e fixer d abord l...

Page 10: ...ue des gants en cuir une chemise en tissu pais des pantalons sans revers des chaussures montantes et un masque D Avant de souder retirer tout produit combustible de ses poches tel qu un briquet au but...

Page 11: ...s et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de causer des interf rences D Le rayonnement haute fr quence peut causer des interf rences avec les quipements de radio navigat...

Page 12: ...andards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Super intendent of Documents P O Box 371954 Pitts...

Page 13: ...head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away fro...

Page 14: ...de label double check all connections jumper link positions and input voltage before applying power S 179 290 1 4 5 3 2 V A V 3 1 96 1 2 3 4 5 6 8 7 9 3 3 Electric Shock And Airflow Label S 179 563 1...

Page 15: ...ubmerged Arc Welding SAW Read Operator s Manual Remote X Duty Cycle Percent U0 Rated No Load Voltage Average U1 Rated Supply Voltage Circuit Breaker U2 Conventional Load Voltage I2 Rated Welding Curre...

Page 16: ...ode 66 VDC 101 5 2 96 5 0 87 4 5 66 3 3 4 48 4 0 56 1250 Amp Volts DC 100 Duty Cycle 10 60 V In CV Mode 66 VDC 5 2 5 0 4 5 3 4 0 56 While idling 4 2 Duty Cycle And Overheating Duty Cycle is percentage...

Page 17: ...lt 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 ST 199 986 A ST 190 97...

Page 18: ...er front access door 4 Plate Label CE Models Only Label located under front access door 5 Rating Label CE Models Only Use rating label to determine input power needs Label located on rear access door...

Page 19: ...mm Including lift eye B 23 in 584 mm B C C 38 in 966 mm Including strain relief D 35 in 889 mm F G H E 1 1 4 in 32 mm 4 Holes F 21 1 8 in 537 mm G 1 1 8 in 29 mm D H 7 16 in 11 mm Dia Weight E 800 45...

Page 20: ...r before connecting to receptacle 1 115 V 15 A AC Receptacle RC9 Power is shared between RC9 Re mote 14 receptacle RC8 and termi nal strip 1T see Section 4 10 2 Circuit Breaker CB1 3 Circuit Breaker C...

Page 21: ...2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 4 4 0 Positive High Inductance used for GTAW TIG And 800 4 0 2 2 0 2 3 0 2 4 0 3 4 0 3 4 0 4 4 0 4 4 0 Positive High Inductance used for GTAW TIG And SMAW Stick applicat...

Page 22: ...ax Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 225 110 90 Normal Operating 3 250 125 110 Min Input Conductor Size In AWG 4 3 0 3 4 Max Recommended Input Conductor Length In Feet Meters...

Page 23: ...0 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flex...

Page 24: ...tch Ground Current Sensor Optional Connect green or green yellow grounding conductor to welding power source groundingterminal first If unit is equipped with optional ground current sensor route groun...

Page 25: ...OM 2223 Page 21 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual...

Page 26: ...OM 2223 Page 22 SECTION 5 OPERATION 5 1 Controls 4 1 2 3 7 8 5 6 Dimension 1000 Nameplate Dimension 1250 Nameplate 4 1 2 3 7 8 5 6 207 729...

Page 27: ...ant Current position digital meters will read 0 zero with contactor off Digital me ters will display actual output voltage and amperage with contactor on With Process Selector switch in the Constant V...

Page 28: ...n weld terminals Repair or replace cracked weld cable 6 Months Blow out or vacuum inside During heavy service clean monthly OR 6 2 Fuse F1 Ref 802 295 Y Turn Off power before open ing rear access door...

Page 29: ...d tighten all weld output connections Unit provides only maximum or minimum weld output Have Factory Authorized Service Agent check control board PC1 and hall device HD1 minimum weld output Check posi...

Page 30: ...age 26 SECTION 7 ELECTRICAL DIAGRAMS 218 515 A For Primary Circuit Diagram Portion refer to the Circuit Diagram located inside the wrapper of the welding power source Figure 7 1 Circuit Diagram for 60...

Page 31: ...OM 2223 Page 27 Figure 7 2 Circuit Diagram for 50 HZ Model 218 516 B For Primary Circuit Diagram Portion refer to the Circuit Diagram located inside the wrapper of the welding power source...

Page 32: ...8 PARTS LIST 802 296 B Figure 8 1 Main Assembly Hardware is common and not available unless listed 50 Hz Models Only 26 33 24 32 31 27 28 1 3 4 5 6 36 2 4 5 26 13 14 15 3 25 22 24 23 1 19 9 12 8 37 17...

Page 33: ...ss intl CE models only 2 26 193 462 BRACKET contactor mount 50 Hz Models Only 2 26 193 462 BRACKET contactor mount 60 Hz Models Only 1 27 163 359 BASE 1 28 T1 218 414 TRANSFORMER pwr main 230 460 575...

Page 34: ...2 297 1 2 3 5 6 7 8 9 10 9 11 9 12 13 14 15 16 17 18 19 20 21 22 23 36 25 26 27 28 29 30 31 32 33 34 24 25 4 Hardware is common and not available unless listed 35 Figure 8 2 Panel Front w Components F...

Page 35: ...17 070 371 BLANK snap in nyl 1 093 1 125mtg hole 1 18 217 865 LABEL warning electric shock and reduced air 1 18 179 563 LABEL electric shock reduce air flow CE models only 1 19 172 587 COVER output st...

Page 36: ...ckey puck 6 6 191 247 HEAT SINK rectifier snowflake3 000 3 7 191 246 CLAMP thyristor rectifier 8 187 3 PLG1 158 720 CONNECTOR SOCKETS 1 TP3 192 731 THERMOSTAT rectifier 1 TP6 168 894 THERMOSTAT rectif...

Page 37: ...c shock input connection CE models only 1 7 R3 097 459 RESISTOR WW fxd 375W 20 ohm 1 8 FM 032 605 MOTOR 1 4HP 230VAC 1625RPM 50 60Hz 1 9 183 167 CONNECTOR clamp cable 2 000 1 802 298 A Hardware is com...

Page 38: ...Notes...

Page 39: ...nd Blankets APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Co...

Page 40: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal S...

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