TM-314C June 1999

Eff. w/Serial Number HE738762

Processes
Stick (SMAW) Welding

Description

Arc Welding Power Source

R
Dialarc 250/250P AC/DC

Visit our website at

www.MillerWelds.com
 TABLE OF CONTENTS
1. Safety Precautions – Read Before Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WARNING
1.2 Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 This product, when used
for welding or cutting,
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 produces fumes or
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 gases which contain
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 chemicals known to the
1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 State of California to
cause birth defects and,
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 in some cases, cancer.
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 (California Health &
2-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Code Section
25249.5 et seq.)
2-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-4. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-5. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-6. Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-8. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-9. Placing Jumper Links And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 4 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 5 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-2. Troubleshooting Circuit Diagram For Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-3. Waveforms For Section 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-4. Input Voltage Labels And Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 6 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 7 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 8 – PARTS LIST FOR HE738762 THRU KJ246631 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 9 – PARTS LIST FOR KJ246632 AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

TM-314C
 SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING
1-1. Symbol Usage
OM-___ - Date, safety_stm 7/98

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

Y 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. Servicing Hazards

Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see FLYING METAL can injure eyes.
the symbol, watch out, and follow the related instructions to
avoid the hazard. D Wear safety glasses with side shields or face
shield during servicing.
Y Only qualified persons should service, test, maintain, and re-
D Be careful not to short metal tools, parts, or
pair this unit.
wires together during testing and servicing.
Y During servicing, keep everybody, especially children, away.

HOT PARTS can cause severe burns.

ELECTRIC SHOCK can kill.
D Do not touch hot parts bare handed.
D Do not touch live electrical parts. D Allow cooling period before working on welding
gun or torch.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from re-
ceptacle, or stop engine before servicing unless the procedure spe-
cifically requires an energized unit. EXPLODING PARTS can cause injury.

D Insulate yourself from ground by standing or working on dry insulat- D Failed parts can explode or cause other parts to
ing mats big enough to prevent contact with the ground. explode when power is applied to inverters.
D Always wear a face shield and long sleeves
D Do not leave live unit unattended. when servicing inverters.
D If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D When testing a live unit, use the one-hand method. Do not put both SHOCK HAZARD from testing.
hands inside unit. Keep one hand free.
D Turn Off welding power source and wire feeder
D Disconnect input power conductors from deenergized supply line
or stop engine before making or changing me-
BEFORE moving a welding power source.
ter lead connections.
SIGNIFICANT DC VOLTAGE exists after removal of D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
input power on inverters.
D Read instructions for test equipment.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any parts.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
STATIC (ESD) can damage PC boards. gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
D Put on grounded wrist strap BEFORE handling support unit.
boards or parts.
D If using lift forks to move unit, be sure forks are
D Use proper static-proof bags and boxes to long enough to extend beyond opposite side of
store, move, or ship PC boards. unit.

FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

D Do not place unit on, over, or near combustible D Keep away from moving parts such as fans.
surfaces. D Keep all doors, panels, covers, and guards
D Do not service unit near flammables. closed and securely in place.

Dialarc 250 AC/DC TM-314 Page 1

 MOVING PARTS can cause injury. H.F. RADIATION can cause interference.
D Keep away from moving parts. D High-frequency (H.F.) can interfere with radio
D Keep away from pinch points such as drive navigation, safety services, computers, and
rolls. communications equipment.
D Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
MAGNETIC FIELDS can affect pacemakers.
D If notified by the FCC about interference, stop using the
D Pacemaker wearers keep away from servicing equipment at once.
areas until consulting your doctor. D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

READ INSTRUCTIONS.
OVERUSE can cause OVERHEATING.
D Use Testing Booklet (Part No. 150 853) when
D Allow cooling period; follow rated duty cycle.
servicing this unit.
D Reduce current or reduce duty cycle before
D Consult the Owner’s Manual for welding safety
starting to weld again.
precautions.
D Do not block or filter airflow to unit.
D Use only genuine replacement parts.

1-3. 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
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
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 research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the 4. Keep welding power source and cables as far away from opera-
committee’s judgment, has not demonstrated that exposure to power- tor as practical.
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as possi-
examined. Until the final conclusions of the research are reached, you ble.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.

TM-314 Page 2 Dialarc 250 AC/DC

 SECTION 2 – INSTALLATION

2-1. Specifications
Amperes Input At Rated Load Output, Amperes Input At Rated Load
50 Hz, Single-Phase Output, 60 Hz, Single-Phase
Model
220 V 260 V 380 V 440 V 520 V KVA KW 200 V 230 V 460 V 575 V KVA KW

AC 68 57.5 39.3 34 28.7 14.9 11 78 68 34 27 15.6 11.8

250P
DC 52 44 30 26 22 11.4 8 57 50 25 20 11.5 8.2

While Idling (21.3) (16.0) (12.2) (10.5) (8.2) (4.5) (0.5) (25) (21.8) (11) (8.9) (5.0) (0.45)

AC 84 -- 48.6 42 -- 18.5 11 103 90 45 36 20.7 11.8

250
DC 68 -- 39.3 34 -- 14.9 11 80 70 35 28 16.1 8.2

While Idling (10.0) -- (5.3) (4.8) -- (2.1) (0.6) (4.1) (3.6) (1.7) (2.2) (0.8) (0.6)

Rated Welding Output: AC Mode 250 A @ 30 Volts AC, 30% Duty Cycle

Rated Welding Output: DC Mode 200 A @ 28 Volts DC, 50% Duty Cycle

Max Open-Circuit Voltage AC 70

Max Open-Circuit Voltage DC 79

2-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
Y Exceeding duty cycle can
damage unit and void
warranty.
30% Duty Cycle At 250 Amperes AC

3 Minutes Welding 7 Minutes Resting

50% Duty Cycle At 200 Amperes DC

5 Minutes Welding 5 Minutes Resting

Overheating
0 A

15
OR
Minutes Reduce Duty Cycle

rduty1 5/95 – SB-002 120-B

Dialarc 250 AC/DC TM-314 Page 3

2-3. 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.

A. DC Mode B. AC Mode

ssb1.1 10/91 – SB-002 696-A / SB–002 689-A

2-4. Dimensions And Weights

Dimensions

Height 26-1/4 in (667 mm)

F Width 19-1/2 in (495 mm)

E Depth 28-1/4 in (718 mm)

D
C A 18-1/4 in (464 mm)

B 1-1/8 in (29 mm)

C 3/4 in (19 mm)

G
8 Holes D 1-1/2 in (38 mm)

E 26-1/2 in (673 mm)

A
F 27-1/4 in (692 mm)

G 1/2 in (13 mm) Dia

Weight
50 Hz: 352 lbs (160 kg)
250 60 Hz: 345 lbs (156 kg)
B ST-157 733-B

50 Hz: 360 lbs (163 kg)

250P 60 Hz: 350 lbs (159 kg)

TM-314 Page 4 Dialarc 250 AC/DC

2-5. Selecting A Location
1 Rating Label
Use rating label to determine input
power needs. Label located on front
panel.
Movement Tipping 2 Line Disconnect Device
Y Do not move or operate unit Locate unit near correct input pow-
where it could tip. er supply.
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.

Location And Airflow

2

18 in
(460 mm)

18 in
(460 mm)
loc_1 3/96 / Ref. ST-111 900-D

2-6. Weld 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
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)

Welding 10 To 60% 60 Thru 100%

10 Thru 100% Duty Cycle
Amperes Duty Cycle 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

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

*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

Dialarc 250 AC/DC TM-314 Page 5

2-7. Connecting To Weld Output Terminals
For DC Weld Output
1 Negative (–) Weld Output
Terminal
2 Positive (+) Weld Output
Terminal
For Electrode Positive (DCEP),
connect work cable to Negative (–)
1 2 terminal and electrode holder cable
to Positive (+) terminal.
For Electrode Negative (DCEN),
reverse cable connections.
For AC Weld Output
3 4 3 Work Weld Output Terminal
4 Electrode Weld Output
Terminal
Connect work cable to Work
terminal and electrode cable to
Electrode terminal.
Close access door.
Y Use only one set of terminals
at a time. Range Selector
switch S2 is only high/low
range; both sets of output
terminals are energized all
the time.

Route weld cables under bar.

Tools Needed:

3/4 in

ST-800 052–A / Ref. S-161 415

TM-314 Page 6 Dialarc 250 AC/DC

2-8. Electrical Service Guide
60 Hertz Models With Power Factor Correction Without Power Factor Correction
Input Voltage 200 230 460 575 200 230 460 575

Input Amperes At Rated Output 78 68 34 27 103 90 45 36

Max Recommended Standard Fuse Or Circuit

125 100 50 40 150 125 70 50
Breaker Rating In Amperes
Min Input Conductor Size In AWG/Kcmil 8 8 12 14 6 8 10 12

Max Recommended Input Conductor Length 131 133 208 200

61 (19) 80 (25) 87 (27) 77 (23)
In Feet (Meters) (40) (40) (64) (61)

Min Grounding Conductor Size In AWG/Kcmil 8 8 12 14 6 8 10 12

Reference: 1993 National Electrical Code (NEC) S-0092-J

Without Power Factor

50 Hertz Models With Power Factor Correction
Correction
Input Voltage 220 260 380 440 520 220 380 440

Input Amperes At Rated Output 68 57 39 34 29 84 49 42

Max Recommended Standard Fuse Or Circuit

100 90 60 50 45 125 70 60
Breaker Rating In Amperes
Min Input Conductor Size In AWG/Kcmil 8 8 10 12 12 8 10 10

Max Recommended Input Conductor Length 157 128 179 153 205
79 (24) 110 (33) 76 (23)
In Feet (Meters) (48) (39) (55) (47) (63)

Min Grounding Conductor Size In AWG/Kcmil 8 8 10 12 12 8 10 10

Reference: 1993 National Electrical Code (NEC) S-0092-J

Dialarc 250 AC/DC TM-314 Page 7

2-9. Placing Jumper Links And Connecting Input Power
Y Have only qualified persons
make this installation. See
rating label in Section 2-5,
and be sure to supply correct
input power.
L1 L2 Check input voltage available at
site.
Remove side panel.
1 Jumper Link Label
Check label – only one is on unit.
Move jumper links to match input
voltage, and label on unit.
2 Input And Grounding
Conductors
See Section 2-8.
3 Line Disconnect Device
See Section 2-8.
Connect input power.
Reinstall side panel.

GND/PE

3
3/8, 7/16, 1/2 in

L1

L2 2

= GND/PE
Y Always connect
grounding conductor first.

200 VOLTS 230 VOLTS 460 VOLTS

L L L L L L

S-083 566-C

260 VOLTS 380 VOLTS 520 VOLTS

L L L L L L
S-047 672-A

230 VOLTS 460 VOLTS 575 VOLTS

Do not overtighten. 1
L L L L L L

S-010 587-B

220 VOLTS 380 VOLTS 440 VOLTS

L L L L L L
S-021 145-B

208 VOLTS 230 VOLTS 460 VOLTS 575 VOLTS

L L L L L L L L

S-035 209-A

input_3 3/96 - ST-111 901-F

TM-314 Page 8 Dialarc 250 AC/DC

 SECTION 3 – OPERATION

3-1. Controls

1 2 3 4

ST-186 137

1 Range Selector Switch Y Do not change position of switch 3 Circuit Breaker CB1
while welding. If CB1 opens, weld output drops to the mini-
Use switch to select ac or dc weld amperage
mum of the range selected, and cannot be
range.
2 Amperage Adjustment Control adjusted by the Amperage Adjustment
If desired amperage is in the overlapping control.
area of two ranges, set switch in the lower Use control to adjust amperage within range Press button to reset breaker.
range for better fine amperage control. selected by Range Selector switch. 4 Power Switch

Dialarc 250 AC/DC TM-314 Page 9

 SECTION 4 – THEORY OF OPERATION
1 Input Terminal Board TE1
Provides means for operation on
different line voltages.
2 Power Switch S1
Provides on/off control of welding
power source.
3 Fan Motor FM
Provides cooling of internal
components.
4 Main Transformer T1
Supplies power to weld output cir- 3
cuit, control circuit, and fan motor
FM. Fan Motor FM
5 Circuit Breaker CB1
Provides overload protection for
transformer T1 30 volts control
winding. 230 VAC
6 Integrated Rectifier SR2
Changes ac output from T1 to full-
1 2 1φ 4 1φ
wave rectified dc.
Primary Secondary
7 Amperage Adjustment Control Single-Phase Input Power Main
Line Input Terminal Switch Transformer
R2 S1 T1
Power Board TE1
Controls weld output by changing
amperage level in magnetic
amplifier MA1.
30 VAC
8 Magnetic Amplifier MA1
5
Controls output current with satura-
tion of its core. Variation of satura- Circuit
tion changes impedance (hin- Breaker
CB1
drance) of amperage flow thereby
varying weld output. A small dc
control current controls a large
amount of weld output current.
9 Range Selector Switch S2 6

Selects coarse range of weld out- Integrated

put from magnetic amplifier MA1. Rectifier
SR2
10 Main Rectifier SR1
Changes ac output from MA1 to full-
wave rectified dc.
11 Capacitors C2 Thru C5,
Suppressor R1, VR1
Protect SR1 from transient
voltages.
12 Stabilizer Z
Smooths welding current.
13 DC Positive (+) And Negative
(–) Weld Output Terminals
Provide dc weld output.
14 AC Electrode And Work Weld
Output Terminals
Provide ac weld output.

Figure 4-1. Functional Diagram

TM-314 Page 10 Dialarc 250 AC/DC
 14 14
AC Work AC Electrode
Weld Output Weld Output
Terminal Work Terminal
Electrode

8 9 10 11
Magnetic Range Main Capacitors C2
Amplifier Selector Rectifier Thru C5,
MA1 Switch S2 SR1 Suppressor R1,
VR1

12

Stabilizer
Z

7 13 13
Amperage DC Negative (–) DC Positive (+)
Adjustment Weld Output Weld Output
Control Terminal Terminal
R2

Work Electrode

AC Or DC Control Circuits

1φ Power

AC Weld Current Circuit

DC Weld Current Circuit

Dialarc 250 AC/DC TM-314 Page 11

 SECTION 5 – TROUBLESHOOTING
5-1. Troubleshooting Table

. See Section 5-2 for test points and values and

Parts List for parts location.

. Use MILLER Testing Booklet (Part No. 150 853)

when servicing this unit.

Trouble Remedy

No weld output; unit completely Place line disconnect device in On position (see Section 2-9).
inoperative.

Check for open line fuse(s), and replace if necessary, or reset circuit breaker (see Section 2-9).

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

Check for proper jumper link position (see Section 2-9).

Check continuity of Power switch S1, and replace if necessary (see Section 5-2).

Check main transformer T1 for signs of winding failure. Check continuity across windings, and check
for proper connections. Check secondary voltage. Replace T1 if necessary (see Section 5-2).

No weld output; fan FM runs. Unit overheated. Allow unit to cool with fan On (see Section 2-2).

Check for proper weld output connections (see Section 2-7).

Check continuity of Range Selector switch S2, and replace if necessary (see Section 5-2).

Check magnetic amplifier MA1 windings for signs of failure. Check continuity between leads 21 and
27, and 21 and 26, and check for proper connections. Replace MA1 if necessary (see Section 5-2).

Check main transformer T1 for signs of winding failure. Check continuity across windings, and check for
proper connections. Check secondary voltages. Replace T1 if necessary (see Section 5-2).

Weld output available; fan FM does Check and clear blocked fan blades.
not run.

Check coil voltage and connectins of fan motor FM, and replace if necessary (see Section 5-2).

Line fuse(s) and/or circuit breakers Check for proper input power connections (see Section 2-9).
open repeatedly.

Check for proper jumper link positions (see Section 2-9).

Check diodes in main rectifier SR1, and replace if necessary (see Section 5-2).

Check main transformer T1 for signs of winding failure. Check continuity across windings, and check
for proper connections. Check secondary voltages. Replace T1 if necessary (see Section 5-2).

For models with power factor correction, check capacitors C6 and C7 (C1 prior to Serial No.
JC659779 on some units) for a short or open. Replace C6 and C7 or C1 if necessary (see Section
5-2).

For models with power factor correction, check continuity of main transformer T1 power factor wind-
ing if present. Replace T1 if necessary (see Section 5-2).

Low weld output. Check for proper weld output connections (see Section 2-7).

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

Check for proper jumper link position (see Section 2-9).

Check diodes in main rectifier SR1, and replace if necessary (see Section 5-2).

TM-314 Page 12 Dialarc 250 AC/DC

 Trouble Remedy

No control of weld output. Reset circuit breaker CB1 if necessary (see Section 3-1).

Check integrated rectifier SR2, and replace if necessary (see Section 5-2).

Check resistance and connections of Amperage Adjustment Control R2; R2 is 0 to 15 ohms ±10%.
Replace R2 if necessary (see Section 5-2).

Check magnetic amplifier MA1 windings for signs of failure. Check continuity between leads 35 and
38, and check for proper connections. Replace MA1 if necessary (see Section 5-2).

Check main transformer T1 for signs of winding failure. Check continuity across windings, and check
for proper connections. Check secondary voltages. Replace T1 if necessary (see Section 5-2).

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

Check connections at input terminal board TE1 (see Section 2-9).

Clean and tighten all weld output connections (see Section 6-1).

Check resistance and connections of Amperage Adjustment Control R2; R2 is 0 to 15 ohms ±10%.
Replace R2 if necessary (see Section 5-2).

Check connections to main rectifier SR1 (dc weld output only) (see Section 5-2).

Check magnetic amplifier MA1 windings for signs of failure. Check continuity across windings, and
check for proper connections. Replace MA1 if necessary (see Section 5-2).

Dialarc 250 AC/DC TM-314 Page 13

5-2. Troubleshooting Circuit Diagram For Welding Power Source

V6
R1
I1
See Section 2-9
for TE1 data

V7/R1

V4/R1

V3/R1

R3

The circuit diagram shown is for 60 Hertz

models. Test points and values apply to
50 Hertz models also.

V2, A, B, C, D
See Section 5-3
for output
waveforms A, B, C, D

Test Equipment Needed:

TM-314 Page 14 Dialarc 250 AC/DC

 Amperage Readings Voltage Readings
a) Tolerance – ±5% unless specified a) Tolerance – ±10% unless specified
I1 2 to 7.8 amperes ac from min to max of b) Reference – to circuit common (Gnd)
Amperage Adjustment control R2 unless noted
I2 0 to 6 amperes dc from min to max of c) Wiring Diagram – see Section 7
Amperage Adjustment control R2
V1 70 volts ac max open-circuit voltage
V2 80 volts dc max open-circuit voltage
V3 80 volts ac
V4 70 volts ac
V5 0 to +24 volts dc from min to max of
Amperage Adjustment control R2
V6 230 volts ac
I2 V7 30 volts ac
R2

V5

Resistance Values
a) Tolerance – ±10% unless specified
b) Turn Off unit and disconnect input
power before checking resistance
R1 All values for T1 are less than 1 ohm
R2 4 ohms
R3 Less than 1 ohm

See Section 5-3

for output
waveforms E, F, G, H
V1, E, F, G, H

SA-090 666-D

Dialarc 250 AC/DC TM-314 Page 15

5-3. Waveforms For Section 5-2

5 ms 20 V 5 ms 20
V

gnd gnd

A. DC Open-Circuit Voltage, Range Selector B. DC Open-Circuit Voltage, Range Selector

Switch S2 In Low Position Switch S2 In High Position

5 ms 20 V 5 ms 20
V

gnd gnd

C. 23.9 Volts DC, 90 Amperes, Range Selector D. 36.4 Volts DC, 137 Amperes, Range Selector
Switch S2 In Low Position (Resistive Load) Switch S2 In High Position (Resistive Load)

TM-314 Page 16 Dialarc 250 AC/DC

 All waveforms shown are for 60 Hertz models.
Waveforms for 50 Hertz models are similar
except distance between peaks is greater.

5 ms 50 5 ms 50
V V

gnd gnd

E. AC Open-Circuit Voltage, Range Selector F. AC Open-Circuit Voltage, Range Selector

Switch S2 in Low Position Switch S2 In High Position

5 ms 50 5 ms 50
V V

gnd gnd

G. 23.6 Volts AC, 84 Amperes, Range Selector H. 40 Volts AC, 160 Amperes, Range Selector
Switch S2 In Low Position (Resistive Load) Switch S2 In High Position (Resistive Load)

Test Equipment Needed:

Dialarc 250 AC/DC TM-314 Page 17

5-4. Input Voltage Labels And Connection Diagrams
1 Input Voltage Label And
Connection Diagram – Only
One Label Is On Unit
2 Terminal Strip TE1

Test Equipment Needed:

Ref. ST-111 901–F / SA-092 209 / SA-145 142 / SA-148 086 / SA-148 087

TM-314 Page 18 Dialarc 250 AC/DC

 SECTION 6 – MAINTENANCE
6-1. Routine Maintenance

Y Disconnect power . Maintain more often

before maintaining. during severe conditions.

3 Months

Replace Repair Or
Unreadable Replace
Labels Cracked
Weld
Cable

3 Months 6 Months

Clean Blow Out

And During Heavy
Or
Tighten Service,
OR Vacuum
Weld Clean Monthly
Inside
Terminals

Dialarc 250 AC/DC TM-314 Page 19

 SECTION 7 – ELECTRICAL DIAGRAMS

. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.

Circuit Wiring
Model Serial Or Style Number
Diagram Diagram

Dialarc 250 AC/DC HE738762 thru HF839493 CA-901 572-1A♦♦

(60 Hertz Models)

HF839494 thru HG076304 CA-901 572-1B♦♦

HG076305 thru HK353363 CA-901 572-1C♦♦

HK353364 thru JD678601 SN-046 182

JD678602 thru KF804650 A-090 666-B♦♦ D-140 350-B♦♦

KF804651 thru KG145817 SA-090 666-C♦♦ D-172 513-A♦♦

KG145818 and following SA-090 666-D SD-184 087

Dialarc 250 AC/DC HE738762 and following SA–090 667-D SD-184 087
(50 Hertz Models)

♦♦ Not included in this manual

SN-046 182

Figure 7-1. Circuit Diagram For Dialarc 250 AC/DC 60 Hertz Models
With Serial No. HK353364 Thru JD678601
TM-314 Page 20 Dialarc 250 AC/DC
 SA-090 666-D

Figure 7-2. Circuit Diagram For Dialarc 250 AC/DC 60 Hertz Models
Effective With Serial No. KG145818 And Following

SB-090 667-D

Figure 7-3. Circuit Diagram For Dialarc 250 AC/DC 50 Hertz Models
Effective With Serial No. HE738762 And Following
Dialarc 250 AC/DC TM-314 Page 21
 Figure 7-4. Wiring Diagram For Dialarc 250 AC/DC 50 And 60 Hertz Models
Effective With Serial No. KG145818 And Following
TM-314 Page 22 Dialarc 250 AC/DC
 SD-184 087

Dialarc 250 AC/DC TM-314 Page 23

Notes

TM-314 Page 24 Dialarc 250 AC/DC

 TM-314C June 1999

Processes
Stick (SMAW) Welding

Description

Arc Welding Power Source

R
Dialarc 250/250P AC/DC

Eff w/HE738762 Thru KJ246631

For OM-314 (029 861) Revisions * Thru T

Visit our website at

www.MillerWelds.com
 SECTION 8 – PARTS LIST FOR HE738762 THRU KJ246631

. Hardware is common and 1

not available unless listed.

8
9

2
7
10

3 6 11

5
12
4
17

14 13
15
Fig 8-5
16

Fig 8-2
ST-133 712-F
Figure 8-1. Main Assembly

TM-314 Page 26 Dialarc 250 AC/DC

 Eff w/HE738762 Thru KJ246631
Quantity
Model
Item Dia. Part Without With
No. Mkgs. No. Description PFC PFC
Figure 8-1. Main Assembly NOTE: Replace coils at Authorized Service Station

. . 1 . . . . . . . . . . . . . . 034 288 .. COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1

. . 2 . . . . . . . . . . . . . . 109 035 .. LABEL, warning electric shock can kill . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 3 . . . . . . . . . . . . . + 034 289 .. PANEL, side (Prior to JK674521) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 3 . . . . . . . . . . . . . + 128 347 .. PANEL, side (Eff w/JK674521 thru KD392621) . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 3 . . . . . . . . . . . . . +161 408 .. PANEL, side (Eff w/KD392622 and on) . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 134 327 .. LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 4 . . . C1 . . . . . . . . 114 543 .. CAPACITOR, polyp met film 40uf 480VAC
(Prior to KF804651 and Eff w/KG148095) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 4 . . C6,7 . . . . . . 172 779 . . CAPACITOR (Eff w/KF804651 thru KG148095) . . . . . . . . . . . . . . . . . . . . . . . 2
. . 5 . . . . . . . . . . . . . . 025 141 . . BRACKET, mtg capacitor
(Prior to KF804651 and Eff w/KG148095) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . ♦027 212 . . BAR, stl hr .250 x 1.500 x 18.000 (see Note) . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 6 . . . . . . . . . . ♦♦♦088 126 . . ANGLE, mtg transformer/stabilizer (see Note) . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 6 . . . . . . . . . . . . . . 092 614 . . ANGLE, mtg front transformer/stabilizer
(Eff w/KA811438 thru KH480261) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 6 . . . . . . . . . . . . . . 092 613 . . BRACKET, mtg transformer & stab
(Eff w/KA811438 thru KH480262) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 6 . . . . . . . . . . . . . . 092 614 . . ANGLE, mtg front transformer/stabilizer
(Eff w/KH480262 and following) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 7 . . . . Z . . . . . . ♦027 218 . . STABILIZER, (see Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 7 . . . . Z . ♦♦♦♦088 088 . . STABILIZER, (see Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 7 . . . . Z . . . . . . . 161 444 . . STABILIZER (Eff w/KD392622 and on) . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 8 . . MA1 . . . . . ♦032 871 . . AMPLIFIER, magnetic (60 Hz) (consisting of) (see Note) . . . . . . . 1 . . . . . 1
. . 8 . . MA1 ♦♦♦♦♦088 097 . . AMPLIFIER, magnetic (60 Hz) (consisting of) (see Note) . . . . . . . 1 . . . . . 1
. . 8 . . MA1 . . . . . . 088 921 . . AMPLIFIER, magnetic (50 Hz) (consisting of) . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 9 . . . . . . . . . . . . . ♦032 836 . . . . COIL, control ac (see Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4
. . 9 . . . . . . . ♦♦♦♦♦088 029 . . . . COIL, control ac (see Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4
. . . . . . . . . . . . . . . . . . . 032 837 . . . . COIL, control dc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 10 . . T1 . . . . . . . 032 904 . . TRANSFORMER, pwr main (Prior to JC659779) (consisting of) . . 1
. . 11 . . . . . . . . . . . . . 032 848 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . T1 . . . . . . . 089 195 . . TRANSFORMER, pwr main 200(208)/230/460 60 Hz)
(Eff w/JC659779) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 11 ............. 088 028 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 10 . . T1 . . . . . . . 089 204 . . TRANSFORMER, pwr main 220/380/440 (50 Hz) (consisting of) . 1
.. 11 ............. 088 204 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 10 . . T1 . . . . . . . 089 198 . . TRANSFORMER, pwr main 230/460/575 (60 Hz) (Eff w/JC659779)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 11 ............. 088 206 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 10 . . T1 . . . . . . . 089 219 . . TRANSFORMER, pwr main 220/380/440 (50 Hz) (consisting of) . . . . . . . . . 1
.. 11 ............. 088 207 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 10 . . T1 . . . . . . . 089 201 . . TRANSFORMER, pwr main 208/230/460/575 (60 Hz)
(Eff w/JC659779) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . 088 205 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . T1 . . . . . . . 032 904 . . TRANSFORMER, pwr main (60 Hz) (Prior to JC659779)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . 032 847 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . T1 . . . . . . . 089 210 . . TRANSFORMER, pwr main 200(208)/230/460 (60 Hz)
(Eff w/JC659779) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 11 ............. 088 027 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 10 . . T1 . . . . . . . 097 296 . . TRANSFORMER, pwr main 260/380/520 (60 Hz) (consisting of) . . . . . . . . . 1
.. 11 ............. 092 427 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 10 . . T1 . . . . . . . 089 213 . . TRANSFORMER, pwr main 230/460/575 (60 Hz) (Eff w/JC659779)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 088 211 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . T1 . . . . . . . 089 216 . . TRANSFORMER, pwr main 208/230/460/575 (60 Hz)
(Eff w/JC659779) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . 088 210 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Dialarc 250 AC/DC TM-314 Page 27
 Eff w/HE738762 Thru KJ246631
Quantity
Model
Item Dia. Part Without With
No. Mkgs. No. Description PFC PFC
Figure 8-1. Main Assembly (Contin-
ued)
. . 12 . . SR2 . . . . . . 095 553 .. RECTIFIER, (Prior to HG076305) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ..... 1
. . 12 . . SR2 . . . . . . 035 704 .. RECTIFIER, integ 40A 800V (Eff w/HG076305) . . . . . . . . . . . . . . . 1 ..... 1
. . . . . . . . C6 . . . . . . . 003 886 .. CAPACITOR, (Eff w/HG076305 thru HK353364) . . . . . . . . . . . . . . . 1 ..... 1
. . 13 . . . . . . . . . . . . Figure 8-5 .. PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ..... 1
. . 14 . . TE1 . . . . . . 146 529 .. TERMINAL ASSEMBLY, pri 1ph 4V . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ..... 1
. . 14 . . TE1 . . . . . . 038 934 .. TERMINAL ASSEMBLY, pri 1ph 3V (Prior to HE754520) . . . . . . . . 1 ..... 1
. . 14 . . TE1 . . . . . . 034 587 .. TERMINAL ASSEMBLY, pri 1ph 3V (Eff w/HE754520) . . . . . . . . . 1 ..... 1
. . 15 . . . . . . . . . . . . . 034 287 .. BASE, (Prior to HE754520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ..... 1
. . 15 . . . . . . . . . . . . ♦034 589 .. BASE, (Eff w/HE754520 – see Note) . . . . . . . . . . . . . . . . . . . . . . . . . 1 ..... 1
. . 15 . . . . . . . . . . ♦♦088 093 .. BASE, (Eff w/see Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ..... 1
. . 15 . . . . . . . . . . . . . 128 398 .. BASE, (Eff w/JK674521 thru KA811437) . . . . . . . . . . . . . . . . . . . . . . 1 ..... 1
. . 15 . . . . . . . . . . . . . 136 172 .. BASE, (Eff w/KA811438 thru KD392621) . . . . . . . . . . . . . . . . . . . . . 1 ..... 1
. . 15 . . . . . . . . . . . . . 161 405 .. BASE, (Eff w/KD392622 thru KH480261) . . . . . . . . . . . . . . . . . . . . . 1 ..... 1
. . 15 . . . . . . . . . . . . . 186 129 .. BASE, (Eff w/ KH480262 and following) . . . . . . . . . . . . . . . . . . . . . . 1 ..... 1
. . 16 . . . . . . . . . . . . Figure 8-2 .. PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ..... 1
. . 17 . . . . . . . . . . . . . 045 201 .. PLATE, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ..... 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦This item was used on units prior to JC659779 excluding JC650714 thru JC650737.
♦♦This item was used on units effective with JC650714 thru JC650737 and JC659779 thru JK674520.
♦♦♦This item was used on units effective with JC650714 thru JC650737 and JC659779 thru KA811437.
♦♦♦♦This item was used on units effective with JC650714 thru JC650737 and JC659779 thru KD392621.
♦♦♦♦♦This item is used on units effective with JC650714 thru JC650737 and JC659779 and following.
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.

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 16)

. . 1 . . . . . . . . . . . . 088 267 .. NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . 032 868 .. PANEL, front (Prior to JA407929) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . ♦045 644 .. PANEL, front (Eff w/JA407929 thru see Note) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . ♦♦088 094 .. PANEL, front (see Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . +112 035 .. PANEL, front (Eff w/JK674521 thru KD392691) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . +161 406 .. PANEL, front (Eff w/KD392692 thru KH480261) . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . 186 131 .. PANEL, front (Eff w/KH480262) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 137 651 .. LABEL, warning electric shock can kill (Prior to KD392692) . . . . . . . . . . . . . 1
. . 3 . . . . S2 . . . ♦032 886 .. SWITCH, range (see Note) (Figure 8-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . S2 ♦♦♦088 087 .. SWITCH, range 2posn (see Note) (Figure 8-4) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . R2 . . . . 083 671 .. RHEOSTAT, WW 150W 15 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . CB1 . . . . 083 432 .. CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . S1 . . . . 025 865 .. SWITCH, tgl DPST 60A 575V (Prior to JB468623) . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . S1 . . . . 045 834 .. SWITCH, tgl DPST 60A 600VAC (Eff w/JB468623 thru KF804650) . . . . . . . 1
. . 6 . . . . S1 . . . . 172 497 .. SWITCH, rotary 2posn DPST w/knob (Eff w/KF804651 thru KG148095) . . 1
. . 6 . . . . S1 . . . . 045 834 .. SWITCH, tgl DPST 60A 600VAC (Eff w/KG148096 and on) . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 039 608 .. PLUG, jack red (Prior to KD392622) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 039 901 .. PLUG, jack black (Prior to KD392622) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . 039 801 .. RECEPTACLE, jack plug black (Prior to KD392692) . . . . . . . . . . . . . . . . . . . 1
TM-314 Page 28 Dialarc 250 AC/DC
 Eff w/HE738762 Thru KJ246631

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 16) (Contin-
ued)
.. 8 . . . . . . . . . . . . 039 800 . . RECEPTACLE, jack plug red (Prior to KD392692) . . . . . . . . . . . . . . . . . . . . . 1
.. 9 . . . . . . . . . . . . 057 608 . . RECEPTACLE, jack plug yellow (Prior to KD392692) . . . . . . . . . . . . . . . . . . 2
.. 7 . . . Neg . . . . 039 046 . . TERMINAL, pwr output black (Eff w/KD392692) . . . . . . . . . . . . . . . . . . . . . . 1
.. 8 . . . POS . . . . 039 047 . . TERMINAL, pwr output red (Eff w/KD392692) . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 9 Elect,Work . 099 255 . . TERMINAL, pwr output neutral (Eff w/KD392692) . . . . . . . . . . . . . . . . . . . . . 2
.. 10 . . . . . . . . . . +161 409 . . DOOR, access front (Eff w/KD392692 thru KH480261) . . . . . . . . . . . . . . . . . 1
.. 10 . . . . . . . . . . . 186 134 . . DOOR, access front (Eff w KH480262 and on) . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 11 . . . . . . . . . . . 605 583 . . CATCH, spr loaded door (Eff w/KD392692 thru KF804650) . . . . . . . . . . . . . 1
.. 11 . . . . . . . . . . . 175 650 . . CATCH, spr loaded door (Eff w/KF804651 thru KG212618) . . . . . . . . . . . . . 1
.. 11 . . . . . . . . . . . 605 583 . . CATCH, spr loaded door (Eff w/KG212619 thru KH480261) . . . . . . . . . . . . . 1
.. 11 . . . . . . . . . . . 089 899 . . LATCH, (Eff w/KH480262 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 12 . . . . . . . . . . . 161 415 . . LABEL, warning electric shock can kill (output studs) (Eff w/KD392692) . . . 1
.. 13 . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary (Eff w/KD392692) . . . . . . . . . . . . . . . 1
.. 14 . . . . . . . . . . . 097 926 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

♦This item was used on units prior to JC659779 excluding JC650714 thru JC650737.
♦♦This item was used on units effective with JC650714 thru JC650737 and JC659779 thru JK674520.
♦♦♦This item was used on units effective with JC650714 thru JC650737 and JC659779 and on.
+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 Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

. Hardware is common and 1 2 3 Fig 8–3 & 4

not available unless listed.

4
5

14

9
8

13
7

12

11 10 ST-002 739-H

Figure 8-2. Panel, Front w/Components

Dialarc 250 AC/DC TM-314 Page 29
 Eff w/HE738762 Thru KJ246631
Item Part
No. No. Description Quantity

032 886 Figure 8-3. Switch, Range (Fig 8-2 Item 3)

...... 1 . . . . . . . . 011 950 . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

...... 2 . . . . . . . . 011 951 . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
...... 3 . . . . . . . . 011 948 . . . GUIDE, contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
...... 4 . . . . . . . . 032 906 . . . PLATE, movable w/components (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
...... 5 . . . . . . . . 103 632 . . . . PLATE, switch toggle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
...... 6 . . . . . . . . 011 645 . . . . CONTACT ASSEMBLY, movable (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
...... 7 . . . . . . . . 011 953 . . . . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
...... 8 . . . . . . . . 011 074 . . . . . . SPRING, pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
...... 9 . . . . . . . . 011 075 . . . . . . SPRING, pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . 10 . . . . . . . . 604 318 . . . NUT, slflkg hex 1/4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . 11 . . . . . . . . 010 805 . . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . 12 . . . . . . . . 019 603 . . . KNOB, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . 13 . . . . . . . . 024 694 . . . BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . 14 . . . . . . . . 103 634 . . . MOUNTING BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . 15 . . . . . . . . 104 935 . . . BRACKET, mtg switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1

9 5 4

7 6
15
8
Includes
Item 9

13

10

14 12

11

ST-032 886-A

Figure 8-3. Switch, Range

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.
TM-314 Page 30 Dialarc 250 AC/DC
 Eff w/HE738762 Thru KJ246631
Item Part
No. No. Description Quantity

088 087 Figure 8-4. Switch, Range 2 Position (Fig 8-2 Item 3)

..... 1 ......... 072 026 . . BRACKET, mtg switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

................. 164 169 . . CIRCUIT ASSEMBLY, switch 2posn (consisting of) . . . . . . . . . . . . . . . . . . . . 1
..... 2 ......... 072 028 . . . . GUIDE, contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..... 3 ......... 011 644 . . . . CONTACT, stationary switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
..... 4 ......... 011 645 . . CONTACT ASSEMBLY, movable switch (consisting of) . . . . . . . . . . . . . . . . . 1
..... 5 ......... 011 075 . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..... 6 ......... 011 953 . . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
..... 7 ......... 011 074 . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..... 8 ......... 072 082 . . BUSHING, stl .265 ID x .484 OD x .593 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..... 9 ......... 072 027 . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . 10 . . . . . . . . 005 558 . . SPRING, selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 2 3

4
5

6
7

9 ST-089 628-A
10

Figure 8-4. Switch, Range 2 Position

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.

Dialarc 250 AC/DC TM-314 Page 31

 Eff w/HE738762 Thru KJ246631
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 8-5. Panel, Rear w/Components Fig 8-1 Item 13)

. . . 1 . . . . . . . . . . . . . 172 502 . . BUS BAR, rectifier (Eff w/KF804651) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . R1,VS1/
R1,VR1 . . +046 819 . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . SR1 . . . . . 027 198 . . RECTIFIER, si diode (Prior to JK674521) (consisting of) . . . . . . . . . . . . . . 1
. . . 2 . . . SR1 . . . . . . 111 935 . . RECTIFIER, si diode (Eff w/JK674521 thru KF804650 (consisting of) . . . 1
. . . . . . . . . . . . . . . . . . . 037 306 . . . . DIODE, rect 150A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . C2-5 . . . . 031 689 . . . . CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 037 305 . . . . DIODE, rect 150A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . SR1 . . . . . 172 504 . . RECTIFIER, si 1ph 250A (Eff w/KF804651) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 172 632 . . BRACKET, mtg rectifier (Eff w/KF804651) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . ♦032 612 . . BLADE, fan 12 in 4wg 23deg .375 bore CCW (see Note) . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . ♦♦♦032 611 . . BLADE, fan 14 in 3wg 19deg .375 bore CCW (see Note) . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 180 165 . . BLADE, fan 14 in 3wg 28 deg (Eff w/KH480262) . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . ♦034 292 . . PANEL, rear (see Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . ♦♦088 091 . . PANEL, rear (see Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 112 036 . . PANEL, rear (Eff w/JK674521 thru KD392621) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 161 407 . . PANEL, rear (Eff w/KD392622 thru KH342518) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 184 245 . . PANEL, rear (Eff w/KH342519 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦005 132 . . WINDTUNNEL, (see Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦♦039 243 . . WINDTUNNEL, (see Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 111 936 . . CHAMBER, plenum 14 in (Eff w/JK674521 thru KF804650) . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 173 283 . . CHAMBER, plenum 14 in (Eff w KF804651 thru KH480261) . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 124 274 . . BRACKET, mtg fan motor (Eff w/KF804651) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 016 074 . . STRIP, adapter conduit (Prior to JK674521) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . FM . . . . . . 116 190 . . MOTOR, 1/12hp 230V 1550RPM 50/60Hz 1.5A . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 111 932 . . JUNCTION BOARD, diode (Prior to KF804651) . . . . . . . . . . . . . . . . . . . . . 2

1 2

4
3

ST-002 760-J
7
Figure 8-5. Panel, Rear w/Components

+Eff w/KF804651 046 819 is included w/Rectifier

♦This item was used on units prior to JC659779 excluding JC650714 thru JC650737.
♦♦This item was used on units effective with JC650714 thru JC650737 and JC659779 thru JK674520.
♦♦♦This item was used on units effective with JC650714 thru JC650737 and JC659779 thru KH480261.
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.
TM-314 Page 32 Dialarc 250 AC/DC
 TM-314C June 1999

Processes
Stick (SMAW) Welding

Description

Arc Welding Power Source

R
Dialarc 250/250P AC/DC

Eff w/KJ246632 And Following

For OM-314 (029 861) Revisions U And Following

Visit our website at

www.Miller-
Welds.com
 SECTION 9 – PARTS LIST FOR KJ246632 AND FOLLOWING

. Hardware is common and

not available unless listed. 1

8
9

2
7
10

3 6 11

5
12
4
17

14 13
15

16 FIG 9-4

FIG 9-2
ST-133 712-G

Figure 9-1. Main Assembly

TM-314 Page 34 Dialarc 250 AC/DC

 Eff w/KJ246632 And Following
Quantity
Model
Item Dia. Part Without With
No. Mkgs. No. Description PFC PFC
Figure 9-1. Main Assembly NOTE: Replace Coils at Authorized Service Station

. . 1 . . . . . . . . . . . . 034 288 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1

. . 2 . . . . . . . . . . . . 109 035 . . LABEL, warning electric shock can kill . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . 3 . . . . . . . . . . + 161 408 . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . 4 . . . . C1 . . . . 114 543 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 5 . . . . . . . . . . . . 025 141 . . BRACKET, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 6 . . . . . . . . . . . . 092 614 . . ANGLE, mtg front transformer & stabilizer . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . 7 . . . . Z1 . . . . 161 444 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . 8 . . . MA1 . . . 088 097 . . AMPLIFIER, magnetic (60 Hz) (consisting of) . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . 8 . . . MA1 . . . 088 921 . . AMPLIFIER, magnetic (50 Hz) (consisting of) . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . 9 . . . . . . . . . . . . 088 029 . . . . COIL, control ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4
. . . . . . . . . . . . . . . . 032 837 . . . . COIL, control dc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. 10 . . . T1 . . . . 089 195 . . TRANSFORMER, pwr main 200(208)/230/460 (60 hz) (consisting of) 1
. 11 . . . . . . . . . . . 088 028 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 10 . . . T1 . . . . 089 204 . . TRANSFORMER, pwr main 220/380/440 (50 Hz) (consisting of) . . . . 1
. 11 . . . . . . . . . . . 088 204 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 10 . . . T1 . . . . 089 198 . . TRANSFORMER, pwr main 230/460/575 (60 Hz) (consisting of) . . . . 1
. 11 . . . . . . . . . . . 088 206 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 10 . . . T1 . . . . 089 219 . . TRANSFORMER, pwr main 220/380/440 (50 Hz) (consisting of) . . . . . . . . . . . 1
. 11 . . . . . . . . . . . 088 207 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 10 . . . T1 . . . . 089 210 . . TRANSFORMER, pwr main 200(208)/230/460 (60 Hz) (consisting of) . . . . . . . . . .
1
. 11 . . . . . . . . . . . 088 027 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 10 . . . T1 . . . . 097 296 . . TRANSFORMER, pwr main 260/380/520 (consisting of) . . . . . . . . . . . . . . . . . . 1
. 11 . . . . . . . . . . . 092 427 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 10 . . . T1 . . . . 089 213 . . TRANSFORMER, pwr main 230/460/575 (60 Hz) (consisting of) . . . . . . . . . . . 1
. 11 . . . . . . . . . . . 088 211 . . . . COIL, ,pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 10 . . . T1 . . . . 089 216 . . TRANSFORMER, pwr main 208/230/460/575 (60 Hz) (consisting of) . . . . . . . 1
. 11 . . . . . . . . . . . 088 210 . . . . COIL, pri/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 12 . . . SR2 . . . 035 704 . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. 13 . . . . . . . . . Figure 9-4 . . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. 14 . . . TE1 . . . 034 587 . . TERMINAL ASSEMBLY, pri 1ph triple voltage . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. 14 . . . TE1 . . . 146 529 . . TERMINAL ASSEMBLY, pri 1ph four voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 15 . . . . . . . . . . . 186 129 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. 16 . . . . . . . . . Figure 9-2 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. 17 . . . . . . . . . . . 045 201 . . PLATE, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2

+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 Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Dialarc 250 AC/DC TM-314 Page 35

 Eff w/KJ246632 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-2. Panel, Front w/Components (Figure 9-1 Item 16)

... 1 .......................... NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . +186 131 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . S2 . . . . . . 088 087 . . SWITCH, range 2posn (Figure 9-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . R2 . . . . . . 083 671 . . RHEOSTAT, WW 150W 15 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . CB1 . . . . . 083 432 . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . S1 . . . . . . 045 834 . . SWITCH, tgl DPST 60A 600VAC scr term . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . Elect,Work . . 099 255 . . TERMINAL, pwr output neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 8 . . . . . Pos . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . Neg . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . +186 134 . . DOOR, access front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . . . 089 899 . . LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . . 161 415 . . LABEL, warning electric shock can kill (output studs) . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . . . 097 926 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. Hardware is common and 1 2 3 FIG 9–3

not available unless listed.

4
5

14

9
8

13
7

12

11 10 ST-002 739-H

Figure 9-2. Panel, Front w/Components

+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 Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

TM-314 Page 36 Dialarc 250 AC/DC

 Eff w/KJ246632 And Following
Item Part
No. No. Description Quantity

088 087 Figure 9-3. Switch, Range 2 Position (Figure 9-2 Item 3)

..... 1 ......... 072 026 . . BRACKET, mtg switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

..... 2 ......... 164 169 . . CIRCUIT ASSEMBLY, switch 2posn (consisting of) . . . . . . . . . . . . . . . . . . . . 1
..... 3 ......... 072 028 . . . . GUIDE, contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..... 4 ......... 011 644 . . . . CONTACT, stationary switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
..... 5 ......... 011 645 . . CONTACT ASSEMBLY, movable switch (consisting of) . . . . . . . . . . . . . . . . . 1
..... 6 ......... 011 075 . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..... 7 ......... 011 953 . . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
..... 8 ......... 011 074 . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..... 9 ......... 072 082 . . BUSHING, stl .265 ID x .484 OD x .593 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..... 10 . . . . . . . . 072 027 . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..... 11 . . . . . . . . . 005 558 . . SPRING, selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. Hardware is common and
not available unless listed.

3
1 2
4

5
6
7
8

11 10 ST-089 628-A

Figure 9-3. Switch, Range 2 Position

Dialarc 250 AC/DC TM-314 Page 37

 Eff w/KJ246632 And Following
. Hardware is common and
not available unless listed.

1 2
5
4
3
6

ST-002 760-K

Figure 9-4. Panel, Rear w/Components

Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-4. Panel, Rear w/Components (Figure 9-1 Item 13)

... 1 ............... 172 502 .. BUS BAR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

... 2 . . . . SR1 . . . . . 172 504 .. RECTIFIER, si 1ph 250A 600PIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 ............... 172 632 .. BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 ............... 173 283 .. CHAMBER, plenum 14 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 ............... 032 611 .. BLADE, fan 14.000 3wg 23deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 ............... 178 126 .. CONNECTOR, cable clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 ............... 184 245 .. PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 ............... 124 274 .. BRACKET, mtg fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . FM . . . . . . 116 190 .. MOTOR, fan 1/12HP 230V 1550RPM 50/60Hz 1.5A . . . . . . . . . . . . . . . . 1

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.

TM-314 Page 38 Dialarc 250 AC/DC

 Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
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

PRINTED IN USA  1999 Miller Electric Mfg. Co.