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Miller Electric 280 NT Welding System User Manual

1. Dimensions A d E All Running Gear Options f 42 1 2 in 1079 mm Height To Top Of Handle Assembly _ C A Protective Cage Width D 26 in 660 mm L c B Running Gear Width gt 32 in 813 mm C Protective Cage Length Y IE 48 in 1219 mm lt A gt B re B gt D Running Gear Length 45 1 2 in 1156 mm 4 5 Fuel Consumption While Welding And Using Generator Power On a typical job using 1 8 in 7018 electrodes 125 amps 20 duty c cycle expect over 20 hours of op ke I eration I _j Welding at 150 amps at 40 duty Re lt cycle uses approximately 3 4 gal Ge O lon per hour or about 16 hours of E U operation a 2 A 2kW generator load at 5096 duty cycle uses less than 1 2 gallon per 7 97 2 00 hour providing over 24 hours of op eration 6 62 1 75 5 67 1 50 A 473 1 25 3600 RPM Weld Lae UH 3 78 1 00 3000 RPM Weld 2 84 0 75 Ge Idle At 4 Generator 1 98 0 50 1800 RPM Generator at4kw FT Generator at 3 kW 0 95 0 25 Generator at2kW at 1 kW 0 00 0 00 0 100 150 200 250 300 DC WELD AMPERES AT 100 DUTY CYCLE 207 967 OM 4430 Page 14 I A
2. Cord Lengths for 120 Volt Loads A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 600 350 106 225 68 137 42 100 30 7 840 400 122 250 76 150 46 100 30 62 19 10 1200 400 122 275 84 175 53 112 34 62 19 50 15 15 1800 300 91 175 53 112 34 75 23 37 11 30 9 20 2400 225 68 137 42 87 26 50 15 30 9 25 3000 175 53 112 34 62 19 37 11 30 3600 150 46 87 26 50 15 37 11 35 4200 125 38 75 23 50 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 800 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69 125 38 75 23 45 10 800 200 61 125 38 50 12 000 175 53 100
3. Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standardfor Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa 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 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l a
4. information Service engine more often if used in severe conditions 17 Check Change Q Clean Replace Reference To be done by Factory Authorized Service Agent Every Section 5 2 8 Hours 1 Fuel Level Y Oil Level Q Oil Fuel Spills Every Section 8 3 25 gt 84 Hours C Spark Arrestor Screen Q Air Cleaner Wrapper Every 50 e Hours p 2 Q Weld Terminals Every Engine 100 Manual Hours Section 8 4 8 5 Q Battery Terminals Q Cooling System MA Air Cleaner Element Every L pan E gt Engine 200 De LES gt f Manual Hours E n Section 8 5 il Unreadable Labels Y Spark Plug Gap O Oil Filter Fuel Filter Every 500 Hours G Weld Cables LO Slip Rings x Brushes OM 4430 Page 33 a193 az 290 661 HATIIN NIBOH SLO O Z HATIIN YITHOM sBnid eds z pue siet Ier pue IO y sepnioul uy Jet pue dn suny seJm pue sGnjd yseds 40jsiseJ Ajuo esf AdtHd8 YON O Z0t L0 S9X UIQOY 222 861 HATIIN NIHOH OAZL OH uoldweug ZOZELZI 18 UOM 200 Z90 HATIIN H3T 1HOM ul Z0 0 dey ORE T ul O 0 0 de5 KEES Jenueyw s JeuMQ 995g pueDe 4N Wl 00 2 0022 peo ON WdH 0SZ S49 peeds UBIH peeds eujbu3 198dde m 481 14 Ap sepn 9uj LV 0L92 E92 UIGOY SSZ 861 HATIIN NIHOH S G0 80 c 18 UOM ZLO 0EZ HATIIN Eure S 0 80 2 J9 UYOY 9LO 0EZ HATIIN H3 HOM ERC sanou 00 Jl JV AeddelM 49414 ly PHI O9IMSS
5. A Welding I A complete Parts List is available at www MillerWelds com Trouble Remedy No weld output Check weld control settings Check weld connections Disconnect equipment from generator power receptacles during start up Increase front panel and or remote control voltage amperage control setting see Sections 6 1 and 6 8 Check and secure connections to Remote receptacle RC4 see Sections 5 7 Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 and PC2 Low weld output Check weld control settings Change position of Engine Control switch and Speed Control switch to achieve desired engine speed Increase front panel and or remote control voltage amperage control setting see Sections 6 1 and 6 8 Check and clean air cleaner as necessary see Section 8 4 Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 and PC2 See engine manual High weld output Check control settings Check for obstructed movement of solenoid linkage Have Factory Authorized Service Agent check circuit boards PC1 and PC2 Weld output cannot be adjusted Have Factory Authorized Service Agent check field current control board PC2 Erratic weld output Check control settings Clean and tighten connections both inside and outside unit Be sure connection to work piece is c
6. 7 2 Variable Frequency Hz Generator Power Receptacle RC3 7 3 Wiring Instructions For Optional 240 Volt Single Phase Plug NEMA 14 50P oO o Oo OO O1 O1 O1 P GO OG h TABLE OF CONTENTS SECTION 8 MAINTENANCE amp TROUBLESHOOTING 33 8 1 Routine Maintenance en A TEE eae Ee ae ae YR UU np ee 33 8 2 iMaintenance Label EE 34 8 3 Servicing Optional Spark Arrestor 2 0 6 ea a DE EEEE EEE eens 35 8 4 Servicing Ait Cleaner rent Mona ee Oo REO eee ae EES 35 8 5 Changing Engine Oil Oil Filter And Fuel Filter 222 36 8 6 Overload Protection see sessile tend niche se ee dd eoe ets 37 8 7 Troubleshooting A8 e kana re sd aaa Se ne e Cae 38 SECTION 9 PARTS LIST 2 5 bol coe de a UR TE 41 9 1 Recommended Spare Parts 41 SECTION 10 ELECTRICAL DIAGRAMS 42 SECTION 11 GENERATOR POWER GUIDELINES 44 COMPLETE PARTS LIST www MillerWelds com OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom 2007 04 A Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous si
7. DES PIECES DE METAL ou DES SA er LETES peuvent provoquer des bles sures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial y LES FUM ES ET LES GAZ peuvent tre dangereux R Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e A l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respira
8. I A complete Parts List is available at www MillerWelds com 7 3 Wiring Instructions For Optional 240 Volt Single Phase Plug NEMA 14 50P 2 The plug can be wired for a 240 V gt gt ar 2 wire load or a 120 240V 3 wire load See circuit diagram 1 Plug Wired for 120 240 V 7 3 Wire Load Current Available in Amperes me When wired for 120 V loads each 240V Each 120 V Duplex wh one half of 240 V receptacle Receptacle Receptacle 2 Plug Wired for 240 V 2 Wire 20 0 Load 15 5 Neutral Silver Terminal 10 10 Load 1 Brass Terminal 5 15 0 20 VxA Watts One 240 V load or two 120 V loads Load 2 Brass Terminal Ground Green Terminal Amperes Available using 120 240 V Plug N OO O1 fF Co Tools Needed gt ER 240 V AC Lol plug1 11 03 120 813 D OM 4430 Page 32 I A complete Parts List is available at www MillerWelds com SECTION 8 MAINTENANCE amp TROUBLESHOOTING 8 1 Routine Maintenance CS Follow the storage procedure in the engine owner s manual if the unit will not be used for an extended period T d we eis A Stop engine before maintaining CL Recycle engine See Engine Manual and Maintenance Label for important start up service and storage fluids
9. 31 Conductor size is based on maximum 2 voltage drop OM 4430 Page 50 Notes SOCKET WRENCH SELECTION TABLE PR SOCKET WRENCH SELECTION TABLE U S STANDARD METRIC Specifications Socket or Wrench Size Specifications Socket or Wrench Size U S De Ge Si SE Tm ESO dani Bolt ER 1 4 in 250 in 3 8 in 7 16 in 6mm 2362 in 10 mm 10 mm 5 16 in 3125 in 1 2 in 9 16 in 8mm 3150 in 14 mm 14 mm 3 8 in 375 in 9 16 in 5 8 in 10 mm 3937 in 17 mm 17 mm 7 6 in 4375 in 5 8 in 3 4 in 12 mm 4724 in 19 mm 19 mm 1 2 in 500 in 3 4 in 13 16 in 14 mm 5512 in 22mm 22 mm 9 16 in 5625 in 7 8 in 7 8 in 16 mm 6299 in 24 mm 24 mm 5 8 in 625 in 15 16 in 1in 18 mm 7087 in 27 mm 27 mm 3 4 in 750 in 1 1 8 in 1 1 8 in 22mm 8661 in 32 mm 32 mm 7 8 in 875 in 1 5 16 in 1 5 16 in 24 mm 9449 in 36 mm 36 mm 1in 1 000 in 1 1 2 in 1 1 2 in OM 4430 Page 51 Notes Welding Symbols Finish Symbol Groove Angle Included Angle of A Countersink for Plug Weld Root Opening Depth of Filling V Groove Weld Size for Plug Welds Fillet Size of Weld N Field Weld Symbol PR o R Weld All J Around Contour Symbol m SE Other Side Reference Line sym
10. A Stop engine before connecting to weld o 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 5 A Do not use worn 100 ft 30 m or Less damaged under 45 m 60 m 70m 90m 105 m 120 m sized or poorly spliced cables 10 60 60 100 AD Duty Duty 10 100 Duty Cycle P Cycle Cycle 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 SE 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 SERO s oo 300 1 50 1 0 60 2 0 70 3 0 95 4 O 120 SR SE EC 2 ea 2 0 2ea 3 0 2 ea 3 0 2 ea 4 0 350 4 0 60 2 0 70 3 0 95 4 0 120 e po TA ed 2 2ea 2 0 2ea 3 0 2ea 4 0 2ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 eae poe ex 20 ex 2 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable 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 mm for metric use S 0007 F For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 5 7 Remote Receptacle Information Engine runs at weld speed 3000 or 3600 rpm whenever a device connected to the remote receptacle is running Lal REMOTE 14 Socket
11. RC31 2 PLG31 1 RC31 1 gt 102 101 02 103 10 tad 76 Is RC26 6 gt RC26 4 gt Y 0000000000000 00000 span DE EXCITER REVOLVING FIELD MAIN FIELD I EDINU a2 000000000000000000 i e RC26 5 gt AT yo SR1 e 111 lar s0 90 e 1 bet g Yip ot d d nil F JE lo c JB Jay M M N N O o c dt VV 42 YTY 7 g S R 105 cB4 120V Le VUS cs bn as SEI F E D C B A N 90 42 T 3 3 11 1 o 1 i i O IT M x AA m AA AAA 581 80 11142 90 52 d 4 120V DO Y We gg V Y Y RC2 ous cn 90 4 roer gt CO e Pe 7D WHT 3 4 22 RC11 3 gt a L t OG rn CR2 PONT CIRCUIT CHASSIS COMMON COMMON 50 87 83 D T P A 64 37 EE E LINE LOAD ACA RC12 3 gt SC xg ROI 240V C48 42 RC13 1 SL LL 142 E RC13 2 gt VOLTAGE FEEDBACK As RC30 2 IE 5 PE L 743 gt ls RS RC13 3 gt PL630 1 RC30 1 4 TAP RC13 4 SLE cv 28 O X o Tees WORK de 141 142 143 744 amp WARNING e Do not touch live electrical parts 1 e Disconnect input power or stop engine before servicing e Do not operate with covers removed ELECTRIC e Have only gualified persons install SHOCK HAZARD use or service this unit 232 961 A OM 4430 Page 43 SECTION 11 GENERATOR POWER GUIDELINES x The views in this section are intended to be representative of all engine driven welding generators Your unit may differ from those shown 11 1 Selecting Equipment Generator Power Receptacles Neutral Bonded
12. Start TIG Scratch Start TIG GTAW Electrode Hot OM 4430 Page 27 CS A complete Parts List is available at www MillerWelds com 6 6 Stick Start Procedure Scratch Start Technique 1 Electrode 2 Workpiece 3 Arc 1 Drag electrode across workpiece like striking a match lift electrode slightly Z4 Gm after touching work If arc goes out LA A lj electrode was lifted to high If electrode sticks to workpiece use a Zeg A quick twist to free it 7 if Pe eg 2 NA y 9 With Stick selected start arc as Wy AZ 42m EE follows 6 7 TIG Lift Arc Start Procedure pe NA y Select Lift Arc Scratch Start TIG at Z SIR E Process switch to achieve great arc NAM CU eR starts with either procedure Perform Lift Arc starting method as follows Lift Arc TIG 1 TIG Electrode 2 Workpiece Turn gas on Touch tungsten Lift Arc Start Method ES electrode to workpiece at weld start SC 1 2 point Hold electrode to workpiece A V for 1 second and slowly lift electrode o 95 Arc is started when electrode is lifted Normal open circuit voltage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between electrode and workpiece The solid state output contactor does not energize until after electrode is touching workpiece This Touch Second allows electrode to touch workpiece without o
13. ce ou le c ble de retour Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit quand on travaille en hauteur Maintenir solidement en place tous les panneaux et capots Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apr s avoir coup l alimentation e Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des composants DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chau des e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures
14. ceptacles use GFCI protected extension cord NOTICE Do not install unit where air flow is restricted or engine may over heat Mounting 1 Cross Supports Mount unit on flat surface or use cross supports to support base Grounding 2 Equipment Grounding Terminal On Front Panel 3 Grounding Cable Not Supplied 4 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire 460 mm Mounting Inadequate support A Do not use flexible mounts 1 Grounding A Bed liners shipping skids and some running gears insulate the welding generator from the vehicle frame Always connect a ground wire from the generator equipment grounding termi nal to bare metal on the vehicle frame as shown Electrically bond generator frame to vehicle frame by metal to metal contact install2 12 06 Ref 800 652 Ref 800 477 A 803 274 A 804 712 OM 4430 Page 18 5 2 Engine Prestart Checks I A complete Parts List is available at www MillerWelds com ad Gasoline Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil CS Follow run in procedure in engine manual This unit has a low oil pressure shutdown switch However some conditions may cause engine damage before the engine shuts down Check oi
15. ne uniquement la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoguer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage Tm i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT e Laisser l quipement refroidir respecter le fac teur de marche nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 4430 Page 10 entrainer des blessures e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer con
16. 4 Installing Exhaust Pipe A Stop engine and let cool G z ES A Engine backfire can cause se vere burns or other injuries Do not point exhaust pipe to ward control panel Keep away from exhaust outlet A Point exhaust pipe in desired direction but always away from front panel and direction of travel RUN IDLE 3600 2400 RPM RUN IDLE 3000 1800 RPM START Tools Needed Ref 216 172 D 803 891 IF 1 2 in Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4430 Page 21 5 5 Connecting To Weld Output Terminals I A complete Parts List is available at www MillerWelds com RUN IDLE 3600 2400 RPM RUN IDLE 3000 1800 RPM START Way 0081 12 HIMOd qd o 120 2404 POWER at 1800 APM CB1 d 25 A MAIN BREAKER 7 SO HZ 120V x ON MEH or O lt MAIN BREAKER Y _ A CN HERREN Do not place anything between weld cable terminal and copper bar Correct Installation Tools Needed IZ 3 4 in
17. 558 OM 4430 Page 16 I A complete Parts List is available at www MillerWelds com 4 9 Stick And MIG Mode Volt Ampere Curves DC VOLTS A CC DC Stick Mode The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of other settings fall between the curves shown 100 80 60 3000RPM Max 40 20 200 B CV DC MIG Mode 400 DC AMPERES 600 S CH 3600RPM Max 09 O1 C o 3000RPM Max DC VOLTS mom o o 20V Preset al Min o al 200 400 DC AMPERES 600 222 555 222 556 222 557 OM 4430 Page 17 I A complete Parts List is available at www MillerWelds com SECTION 5 INSTALLATION 5 1 Installing Welding Generator A Do not weld on base Welding on base can cause fuel tank fire or explosion Bolt unit down using holes provided in base A Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes A Do not mount unit by support ing the base only at the four mounting holes Use cross supports to adequately sup port unit and prevent damage to base A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards A If unit does not have GFCI re
18. Have Factory Authorized Service Agent check brushes and slip rings and circuit boards PC1 PC2 and PC7 Low generator power output at ac re ceptacle RC3 Turn Engine Control switch to Run Idle 3600 2400 RPM position OM 4430 Page 39 D Engine I A complete Parts List is available at www MillerWelds com Trouble Remedy Engine will not crank Check fuse F6 and replace if open see Section 8 6 Check battery voltage Check battery connections and tighten if necessary Check plug PLG5 and plug PLG8 connections Have Factory Authorized Service Agent check Engine Control switch S2 Engine does not start Check fuel level see Section 5 2 Check battery and replace if necessary Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual Check engine charging system according to engine manual See engine manual Engine starts but stops when Engine Control switch returns to either Run Idle position Check oil level See Section 5 2 Low oil pressure shutdown stops engine if oil pressure is too low Engine also stops if oil level is too high Use correct grade oil for operating temperature see Section 8 2 Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 Battery discharges between uses Place Engine Control switch in Off position when unit is not running Cle
19. Idv WO pepueuiuio2eH jeg 49949 0 uepuerosep A 00 ue uezueliuoo seJou SLI 911992 ep OIQUIEI ep sejue uepanb enb seJoy se Jon eed nuejej eu2Jeu 31dI Nnu uoioisod ej ue HOLOW 140 7OH NOO Ie eBuod opebede Jojow ja uoo ALIASY 20 OIGINVD 13d OTVAHALNI e 40 OW je ue SBJOY Se Jon amp Jed euoJeu NOY uolaisod e ue 1030W ep jojuoo ja ebuod opebede ozow je uoo OULANOUOH xS3HOdiaaN SOT 3d OLN3BIWIN31NVMW 3G SINOIONNA 0 MS 02 MS enuen sumo ees pueDe7 N 1044 Ae dsip jose 03 yo aulyoeu Un e Ade 9LF SI ALIN S WdH peeds uni pue ejp UO Jes pue 49949 o esf s Ade euiBu3 fejdsip Wan s163eu pue seun E uonisod MH 0 3 1a NnH eut Woy uos onuog euiDu3 d uonisod LOH yong Aue ui uoIMS J0j2eJes sseo2oJd eu pue Buiuuni euiBue YUM S NdH 3NISN3 Seu g uonisod NNY 03 3 1al NnH 24 Woy OMS joQUOD eujBu3 81949 13538 OL Temau eDueuo lo pepueuiuio98 jsed ueuM pejeoipur sinoy eAneBeN JLON enp eBueuo jio y 0 umop 1unoo pue 00 Je MIS sinoy UO eDueuo jio 3xeu eJ0Jeq sanoy ees o3 uonisod 31GI NNY eu ozu YOUMS Jojuo euiDu3 ee yo euiDue YM TYAHSLNI 3ONVHO 110 s sinoy euiBue MBIA 0 UOHISOd NNY U uos jonuo uuz esejd yo euiBue ur HALIN HNOH e SNOLLONN4 3ONVNALNIVN yalan SHNIDNS SVO S9H3 P9H3 NISOH EZHI 0ZH9 H3T1HOM OEMS pol RS Ov MO O MOI LGE 0 0 MOL 1 Maintenance Label 8 2 Follow the storage procedure in the engine owner s manual if the unit will
20. Incorrect Installation A Stop engine A Do not connect to CC and CV terminals at the same time 1 Negative Weld Output Terminal 2 Stick TIG CC Weld Output Terminal 3 Wire CV Weld Output Terminal For MIG welding connect work cable to Negative terminal and wire feeder cable to Wire CV terminal For Stick welding connect work cable to Negative terminal and electrode holder cable to Stick TIG CC terminal For TIG welding connect work cable to Stick TIG CC terminal and elec trode holder to Negative terminal A Failure to properly connect weld cables may cause exces sive heat and start a fire or damage your machine 4 Weld Output Terminal 5 Supplied Weld Output Terminal Nut 6 Weld Cable Terminal 7 Copper Bar Remove supplied nut from weld out put terminal Slide weld cable termi nal onto weld output terminal and se cure with nut so that weld cable termi nal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean 216 172 D 803 984 A 803 778 A OM 4430 Page 22 5 6 Selecting Weld Cable Sizes I A complete Parts List is available at www MillerWelds com Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding Weld Output Terminals
21. Q Miller OM 4430 217 243R 2007 04 Processes Stick SMAW Welding TIG GTAW Welding am MIG GMAW Welding amp N Flux Cored FCAW Welding With Voltage Sensing Feeder Description O Ed Ez Engine Driven Welding Generator Miller Legend 302 U Visit our website at www MillerWelds com File Engine Drive w i 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 build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U E Bl E PEENI This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hard as you do A every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation q
22. See Section 7 2 Place switch in Weld position to allow engine speeds to be determined by position of En gine Control switch The Speed Control switch is not needed at start up 6 3 Cold Weather En ine Operation 1 Engine Control Switch Carburetor Icing Carburetor icing causes the unit to drop below the normal idle speed and then stall This condition occurs when the temperature is near freezing and the relative humid ity is high Ice forms on the throttle plate and inner bore of the carburetor The engine typically restarts without problems but soon stalls again Infrequently Loaded RUN IDLE 3600 2400 RPM e Treat gasoline with a fuel de icer product isopropyl alcohol e Place the Engine Control switch in the Run position RUN IDLE 3000 1800 RPM Run engine only when expecting to frequently load it START Breather Icing Oil breather pulse line icing occurs in severe cold continuously below 0 F Mois ture accumulates in the oil from piston ring blow by if the engine is extensively idled This may cause vacuum line freezing oil breather tube freezing or ice in the carbure tor All of these cause operating problems Due to ice in the lines the engine may not restart until it is warmed to above freezing Load engine and reduce idle times to prevent engine shutdowns Use an electric fuel pump to avoid pulse line freezing Frequently Loaded Install engine cold weather
23. Volt Ampere Curves 4 9 Stick And MIG Mode Volt Ampere Curves SECTION 5 INSTALLATION 00 0c cece eee II Henne 5 1 Installing Welding Generator 5 2 Engine Prestart Checks 5 3 Connecting Or Replacing The Battery 5 4 Installing Exhaust Pipe 0 eee 5 5 Connecting To Weld Output Terminals 5 6 Selecting Weld Cable Sizes 5 7 Remote Receptacle Information SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls 6 2 Description Of Engine Controls See Section 6 1 6 3 Cold Weather Engine Operation 6 4 Controlling Engine Speed And Weld Generator Output 6 5 Process SWIICh a recae uo dee ee e crake 6 6 Stick Start Procedure Scratch Start Technique 6 7 TIG Lift Arc Start Procedure 6 8 Remote Voltage Amperage Control SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 60 Hz Generator Power Receptacles And Supplementary Protectors
24. bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pastenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenirle chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curit 2 3 Dangers existant en relation avec le moteur L EXPLOSION DE LA BATTERIE peu RENDRE AVEUGLE e Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une intervention sur la batterie Arr ter le moteur avan
25. complete Parts List is available at www MillerWelds com 4 6 Generator Power Curve The ac generator power curve shows the generator power avail able in amperes at the receptacles 300 250 en 200 z I 150 O X 100 50 0 0 5 10 15 20 25 30 AC AMPERES 222 553 WELD POSITION FLAT HORIZONTAL VERTICAL OVERHEAD WELD JOINT BUTT BUTT 1G BUTT T un 3G E T JOINT GROOVE ud 2F FILLET T JOINT Ref AWS ANSI D1 1 1F Ref 804 248 A OM 4430 Page 15 I A complete Parts List is available at www MillerWelds com 4 7 Duty Cycle 100 Duty Cycle at 280 Amperes DC CC Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty Continuous Welding 325 300 275 250 225 Sauadiv 13M 200 175 150 0 10 20 30 40 50 60 70 80 90 100 DUTY CYCLE Ref 207 925 4 8 TIG Mode Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of other settings fall between the curves shown 35 3600RPM Max 3000RPM Max Min DC VOLTS D D o mb O O O O O 0 100 200 300 400 DC AMPERES 222
26. d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 2 7 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus particuli rementles enfants I gt gt UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne compor tant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre Ne passe servir de source lectrique courant lectriq
27. is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as micro processors computers and computer driven equipmentsuch as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines A Engine exhaust contains chemic
28. kit Kohler offers a kit for cold weather operation Contact engine manufacturer for kit information 1 800 544 2444 The user can install these kits The kit pulls heated air from the muffler surface into the carburetor and shuts the cold air off This in creases engine temperature during operation in both idle and high speed OFF RUN IDLE 3600 2400 RPM RUN IDLE 3000 1800 RPM E When the ambient temperatures become warmer above 45 F the air flow will START have to be returned to normal Ref 216 172 OM 4430 Page 25 I A complete Parts List is available at www MillerWelds com 6 4 Controlling Engine Speed And sites cali Output Ph AS M CERS Engine Controls coy Soule Weld Output Engine Speed Either G Run ldle Oy comma position 1800 rpm oum Power Speed Welding Not AS Continuous Recommended 5 kW kVA Total From All AC Receptacles No Load 2400 rpm Idle Speed AA A a SE ch 2 4 KW KVA at 60 120 Weld Spoed Hz From AC Receptacle RC3 Only Q no ee 5 KW KVA Total From a All AC Receptacles 3000 rpm Load 3000 rpm At 1800 rpm 20 220A Weld Speed At 3000 rpm Output Available Only At 2 4 kW kVA 60 120 Hz AC Receptacle RC3 gt Set engine controls as shown to obtain the corresponding weld and generator power out put NOTICE Disconnect equipment from auxiliary p
29. not be used for an extended period OM 4430 Page 34 I A complete Parts List is available at www MillerWelds com 8 3 Servicing Optional Spark Arrestor EU Tools Needed IF 1 4 in My A Stop engine and let cool 1 Spark Arrestor Screen Clean and inspect screen Replace spark arrestor if screen wires are broken or missing RUN IDLE 3600 2400 RPM RUN IDLE 3000 1800 RPM START 803 983 A Ref 216 172 D 8 4 Servicing Air Cleaner Wer OFF RUN IDLE 3600 2400 RPM RUN IDLE 3000 1800 RPM START A Stop engine NOTICE Do not run engine with out air cleaner or with dirty element 1 Precleaner Wash precleaner with soap and wa ter solution Allow precleaner to air dry completely Spread 1 tablespoon SAE 30 oil evenly into precleaner Squeeze out excess oil 2 Element Replace element if damaged dirty or oily aircleaner3 11 04 802 772 S 0759 OM 4430 Page 35 CS A complete Parts List is available at www MillerWelds com 8 5 Changing Engine Oil Oil Filter And Fuel Filter pu A d apr LAY A Stop engine and let cool y ZA 1 Oil Drain Valve 2 OU Filter Change engine oil and filter accord ing to engine manual NOTICE Close valve and valve RUN IDLE feodi BPM cap before adding oil and running RUN
30. out AY ujw sduiy Or 9 81 4 0 1 eoueuuoyed Bupuelo gg dnou9 198 i EV 21099 93 UIGOY v86 SLZ HATIIN NIGOH ZC0SOSC 19140 v86 SLE HATIIN Hx 1HOM NIE Ze pepeejun f egeg HOA ZL ITI e223 19114 19N4 epein any I A complete Parts List is available at www MillerWelds com ouenp jap jenueui je BAA JN ep pueBe e PIB de eljejued ej Jeunes esed euinbeui e enBedy sWdH 91 se uoisioeJd e euoJeui uae ep sepepioojeA seque Je i A seenbayo red ojos HOLOM 130 WdH Ie UEIEISOU saJopipau soj A segen NnH Y TIGI NNH uoroisod E ep JOJOW JEP 0 JU09 e 81919 LOH A9NS uoioisod eigeinbse eno ue osesosd Je 42 023U09 ep 1o1dn uejui ja A opueuorounj J0 OW 8 UCD HOLOMW 130 SWdH e S899A se Nn Y TICI NNH uoloisod ei ep JOJOW ep JONUOI 9 ep HVIAHV3H Ved y Jep oiquieo jap OJeAleju je opesed aiqos e es enb ueoipui seAgeDeu se10H JLON 01028 j JeIquieo ep oyueuiouJ 10pIpaul ap so2eny SOP so eJue ej ege jap jenu jo ePBuajuey 7NIGOU 4opipeui ep 4 7 Se9 eu SE eJue ey ee ep jenju ja eDuejue Ww EN e VC SNATIAHAOS ON yORSdjp uo sejoy z UBEMjaq Jana 0 deey NIgou ronsdip uo SILU 4 Y 7 ueeMjeq 8 8 E wl e K 11IAHAAO LON OG suenb g Ajayewixoiddy eBueuo Jeu w yoedeo 110 00 108S9 8bZ UIQOH YSZ 861 HITIIW NIHOH 1005031 19140 869 990 HATIIN H31HO 9 sinou 002 sinou OO lo oeuuAs esn lony d1 Buisn y J04B y JO DS UOREOLISSEID eajues
31. state and local codes Customer supplied equipment is required if generator will sup ply standby power during emergencies or power out ages 1 Utility Electrical Service 2 Transfer Switch Double Throw Switch transfers the electrical load from electric utility service to the generator Transfer load back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring Connect generator with temporary or permanent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low volt age and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the prem ises If generator does not produce enough output to meet all require ments connect only essential loads pumps freezers heaters etc See Section 11 4 OM 4430 Page 49 11 11 Selecting Extension Cord Use Shortest Cord Possible SN
32. to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process e If AC output is required use remote output control if present on unit e Additionalsafety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes IF Indicates special instructions AEN This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related inst
33. AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Conta
34. D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l ali mentation est correctement dimensionn e et prot g e avant de mettre l appareil en service MIC LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage pour lever l appareil et les accessoires correctement install es seuls PAS les bouteilles de gaz Ne pas d passer le poids nominal maximal de l ceilleton voir les sp cifications e Ne lever et ne soutenir l appareil qu avec de l quipement appropri et en suivant les proc dures ad quates e Enutilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil OM 4430 Page 9 LE SURCHAUFFEMENT peut endom mager le moteur lectrique Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur e Ne pas laisser tourner le moteur trop lentement sous risque d en dommager le moteur lectrique cause d une tension et d une fr quence trop faibles e Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz n LES TINCELLES VOLANTES ris quent de provoquer des blessures N e Porter un cran facial pour prot ger le visage et les yeux e Aff ter l lectrode au tungst
35. IDLE engine 3000 1800 RPM Fill crankcase with new oil to full mark on dipstick see Section 8 2 3 Fuel Filter 4 Fuel Line Replace line if cracked or worn Install new filter Wipe up any spilled fuel Start engine and check for fuel leaks A Stop engine tighten connec tions as necessary and wipe up fuel Tools Needed GP OM 4430 Page 36 803 983 A Ref 216 172 D S 0842 I A complete Parts List is available at www MillerWelds com 8 6 Overload Protection 4 er A Stop engine Open left side door EF When a supplementary protec tor or fuse opens it usually indi cates a more serious problem exists Contact a Factory Au thorized Service Agent 1 Supplementary Protector CB4 CB4 protects the stator winding supplying 24 volt ac output to Re mote receptacle RC4 If CB4 opens 24 volt ac output to RC4 stops RUN IDLE 3600 2400 RPM RUN IDLE 3000 1800 RPM START Supplementary Protector CB3 protect the stator winding sup plying 115 volt ac output to Re mote Receptacle RC4 see Section 7 1 Press button to reset 2 Fuse F6 See Parts List F6 protects the engine wiring sys tem from overload If F6 opens engine will not crank Replace fuse if open Close left side door 803 773 A Ref 216 172 D OM 4430 Page 37 8 7 Troubleshooting
36. LER ENGINE E UNIT ERC PC2 REMOTE E 3 CONTROL PCB 4 FIRGCGD zou CIRCUIT COMMON 2 1 RC4 A 705 6 5 3 1 4 2 24VAC SOURCE gt 1 A PLG5 A PLCS row PLGS APLGS T A PUER 2AVAC CONTACTOR gt e a lt lt RC14 6 wO Z PRESSURE RED RED VEL REMOTE COMMAND SRCE 4 _ lt erci4 s NO GS1 CIRCUIT COMMON BELH 708 enc g_3 t 9 I RC4 C 07 AED Di COMMAND REF gt 17 MXRC14 4 m L ELECTRONIC 1isvac contactor SRCIH A KRC14 8 Le GOVERNOR en 112 who gt 22 lt R014 2 U NT 4 22 des 10 1004 SRCE 7 2 een k 12 VOLT S RC4 11 E En PD 115VAC SOURCE E CHASSIS COMMON m A a ALTERNATOR STATOR VOLT REG RECT TI TT TT LP KOHLER ENGINE J OM 4430 Page 42 Figure 10 1 Circuit Diagram For Welding Generator Models EX il CITER FIELD COMMON MAIN FIELD im BEARING 1 RC26 2 gt paz RC28 3 SA COLLECTOR RINGS Rc25 2 gt ZE AXE RC25 3 gt PLO31 4 RC31 4 NER PLO31 3 RC31 3 P a Tiar PLG31 2
37. Socket Information 24 VOLTS AC A eu eE ac Protected by supplementary protector OUTPUT CONTACTOR B Not used 115 VOLTS AC l 115 volts ac Protected by supplementary protec tor CB3 OUTPUT CONTACTOR J Not used C 10 volts dc output to remote control AN D Remote control circuit common AMPERAGE VOLTAGE E 0 to 10 volts dc input command signal from remote control Circuit common for 24 and 115 volts ac circuits GND Chassis common The remaining sockets are not used OM 4430 Page 23 I A complete Parts List is available at www MillerWelds com SECTION 6 OPERATING WELDING GENERATOR Front Panel Controls 6 1 NEUTRE RACCORDE AU BATL 1 Process Switch See Section 6 5 for Process switch informa tion 2 Remote Receptacle Use receptacle to connect remote control When a remote voltage amperage control is connected to the Remote receptacle the Auto Sense Remote feature automatically switches voltage amperage control to the re mote control see Sections 5 7 and 6 8 With remote voltage amperage control con nected weld output in CC mode is deter mined by a combination of front panel and re mote control voltage amperage settings If no remote voltage amperage control is connected to the Remote receptacle the front panel Voltage Amperage control ad justs voltage and amperage 3And4 Displays Displays can show weld process information voltage and amperage or maintenance
38. To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment I Be sure equipment has double A insulated symbol and or word ing on it Do not use 2 prong plug un less equipment is double in sulated gen pwr 2007 04 Ref ST 159 730 ST 800 577 A A 1 2 3 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire gt Electrically bond generator A frame to vehicle frame by met al to metal contact Bed liners shipping skids and some running gear insu late the welding generator from the vehicle frame Al ways connect a ground wire from the generator equip ment grounding terminal to bare metal on the vehicle frame as shown If unit does not have GFCI re ceptacles use GFCI pro tected extension cord S 0854 OM 4430 Page 44 11 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device EF Use ground device as s
39. acle RC1 120 V x 10 A 240 V x 16A 2 5 KVA KW Ref 211 909 OM 4430 Page 30 7 2 Variable Frequency Hz Generator Power Receptacle RC3 I A complete Parts List is available at www MillerWelds com PIM amp 120 240V X CB1 25 AMAIN BREAKER ON II St OFF CB2 ZN cB3 O O 7 Ue 2 0 amp tr Bo g O 5 g M om loj E sh 4 zm D 24 SER 120V MAIN BREAKER 2 NOTICE Do not operate equipment requiring a constant frequency from variable frequency receptacle RC3 1 120 V 20 A Variable Frequency AC Receptacle RC3 Receptacle supplies single phase power continuously Freguency Hz of generator power output changes with engine speed Total output avail able is 2 4 KVA kW 2 Supplementary Protector CB3 CB3 protects receptacle RC3 and 115 volt ac output to Remote Recep tacle RC4 from overload If CB3 opens the receptacle does not work and 115 volt ac output at RC4 stops I Press button to reset If supple mentary protector continues to open contact a Factory Autho rized Service Agent Ref 216 172 D Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4430 Page 31
40. afety Standards 1 8 EMF Information esoe dE AA A n RAA SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 2 1 Signification des symboles 2 2 Dangers relatifs au soudage l arc 2 3 Dangers existant en relation avec le moteur 2 4 Dangers li s Pair comprim 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 2 6 Proposition californienne 65 Avertissements 2 7 Principales normes de s curit 2 8 Information EMF 2 css saepe e d dE o SECTIONS DEFINITIONS 5 2 kr a eee 3 1 Symbol Definitions SECTION 4 SPECIFICATIONS 000 cece cece eee eee eee n nnn nne 4 1 Description 1 5 s tee Rae imde ke ees cease dhe ae dd 4 2 Weld Power And Engine Specifications 4 3 Dimensions Weights and Operating Angles 4 4 Dimensions For Units With Optional Running Gear 4 5 Fuel Consumption While Welding And Using Generator Power 4 6 Generator Power Curve 4 7 Duty Cycle ker nomen en EEG eA ue emm RUN 4 8 TIG Mode
41. als known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standardfor Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa 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 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cable
42. an top of battery with baking soda and water solution rinse with clear water Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator according to engine manual Engine stopped during normal operation Check fuel level see Section 5 2 Check oil level see Section 5 2 Low oil pressure shutdown stops engine if oil pressure is too low Engine also stops if oil level is too high Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual Engine does not return to idle speed Place Engine Control switch S2 in either Run Idle position Remove all weld and generator power loads Turn off remote contactor The unit will not return to idle speed when the remote contactor is on Turn off remote device connected to Remote receptacle RC4 see Section 5 7 Check for obstructed movement of solenoid linkage Have Factory Authorized Service Agent check circuit board PC2 and current transformer CT1 Engine does not go to weld speed Place Speed Control switch in Weld position Check for obstructed movement of solenoid linkage During operation in near freezing tem peratures engine starts and goes to idle but stalls after a few minutes Treat fuel with isopropyl alcohol de icer product Place Engine Contr
43. arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection FM WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side OM 4430 Page 2 Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding curr
44. ased upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION
45. ated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use ap proved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the
46. b et des compos s a base de plomb produits chimi ques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation 2 7 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 8 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques I
47. bol E 7 a E EM J Groove L P Tail A Line Weld Symbol Length of Weld Pitch Center to Center Spocing OM 4430 Page 52 Both Sides Arrow Side V Groove U Groove Q Ref AWS ANSI A2 4 T Square Groove Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way C Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY S EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or repla
48. bserve correct polarity and on batteries Disconnect negative cable first and connect it last FUEL can cause fire or explosion e Stop engine and let it cool off before checking or adding fuel e Do not add fuel while smoking or if unit is near any sparks or open flames Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Dispose of rags in a fireproof container Always keep nozzle in contact with tank when fueling MOVING PARTS can cause injury e Keep away from fans belts and rotors v e Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove doors panels covers or guards for maintenance and troubleshooting as necessary e To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall doors panels covers or guards when servicing is finished and before starting engine e Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting Block flywheel so that it will not turn while working on generator components HOT PARTS can cause severe burns Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot par
49. cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 7 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 8 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still
50. ce any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipmentto the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowme
51. ct your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 Miller Electric Mfg Co 2007 01 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 amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com C Miller
52. de s curit Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection FRA LE SOUDAGE peut provoquer un in o cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchaut fement ou un incendie Avant de commencer le soudage v rifier s assurer que l endroit ne pr sente pas de danger D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec des protections homologu s Ne pas souder dans un endroit l ou des tincelles peuvent tomber sur des substances inflammables Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud Des tinc
53. ds or parts Use proper static proof bags and boxes to store move or ship PC boards Use tongue jack or blocks to support weight Properly install welding generator onto trailer y E TILTING OF TRAILER can cause injury e according to instructions supplied with trailer READ INSTRUCTIONS Read Owner s Manual before using or servic ing unit Use only genuine replacement parts from the manufacturer Perform engine and air compressor mainte nance and service according to this manual and the engine air compressor if applicable manuals H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained 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 1 6 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases
54. elles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proximit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple Brancher le cable de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites ge l es En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes Une fois le trava
55. ent from traveling long possibly unknown paths and causing electric shock sparks and fire haz ards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby n NOISE can damage hearing Noise from some processes or equipment can dam age hearing e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pres sure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefu
56. ep tacles RC1 and RC2 only at 1800 rpm If generator is not locked at 1800 rpm engine speed increases in response to weld load and generator power output stops at receptacles RC1 and RC2 Generator power load does not affect engine speed Engine Choke Control Use control to change engine air fuel mix when starting engine To Start pull out choke and turn Engine Control switch to Start position Release switch and slowly push choke in when engine starts With Speed Control switch in Weld the engine starts at 3000 rpm and remains there for two minutes Engine speed then reduces to 2000 rpm The engine speed reduces from 3000 rpm to 2000 rpm when the Speed Control switch is toggled within the first two minutes of operation and no load is applied When an auxiliary power load is applied to 60 Hz receptacle RC1 or RC2 engine speed reduces to 1800 rpm CS If the engine does not start let the engine come to a complete stop before attempting restart gt During cold weather some gasoline en gines encounter difficulties that are easi ly remedied See Section 6 3 and 8 7 To Stop turn Engine Control switch to Off position Engine Speed Control Switch Use switch to control engine auto idle func tion Place switch in Generator Lock position when not welding to lock engine speed at 1800 rpm for generator power at 60 Hz ac re ceptacles RC1 and RC2 generator power is always available at 60 120 Hz receptacle RC3
57. h in either Run ldle position LED s indi cate fuel left in tank 6 Voltage Amperage Control Use control to select weld voltage or amperage Control may be adjusted while welding I For maximum weld output above 220 Amps run unit at 3600 rom For weld output below 220 Amps operate unit at 3000 or 3600 rpm With Process switch in any Stick or TIG set ting use control to adjust amperage With Process switch in Wire position use control to adjust voltage When a remote voltage amperage control is connected to Remote receptacle RC4 control sets the maximum amperage in Stick and TIG modes but has no effect in MIG mode 7 Engine Control Switch see Section 6 2 8 Engine Choke Control see Section 6 2 9 Engine Speed Control Switch see Sec tion 6 2 OM 4430 Page 24 I A complete Parts List is available at www MillerWelds com 6 2 Description Of Engine Controls See Section 6 1 Engine Control Switch Use switch to start engine select speed and stop engine Use switch in combination with Engine Speed Control switch to select en gine speed In Run Idle 3600 2400 RPM position engine runs at 2400 rpm no weld load and 3600 rpm under weld load In Run Idle 3000 1800 RPM position engine runs at 1800 rpm no weld load and 3000 rpm under weld load In either position engine speed is deter mined by weld load and position of Engine Speed Control switch Generator power is available at rec
58. ial variable frequency 60 120 Hz receptacle provides 2 4 kW kVA 120 Volt AC generator power continuously 4 2 Weld Power And Engine Specifications r Rated Maximum Amperage Voltage peer Welding Open Circuit Range In Range In SE odes Engine Output Voltage CC Mode CV Mode 9 pacity 5 5 kVA kW Peak 5 kVA kW Continuous o 42 21 A cepo 2804 25 V 100 50 20 300 A 120 240 V AC Kohler CH 23 Duty Cycle i 60 Hz Air Cooled Single Phase at 12 gal Two Cylinder een m EE s 25 HP LP Engine 2 4 KVA KW 20 A w Electronic CV DC 300 A 25 V 100 35 120 VAC Governor Duty Cycle 60 120 Hz Single Phase At All Speeds 4 3 Dimensions Weights and Operating Angles Dimensions Height 34 in 864 mm Width 20 1 2in 621 mm Depth 45 1 2 in 1156 mm A 20 in 508 mm B 16 1 2 in 419 mm C 1 3 4 in 44 mm D 5 in 127 mm E 32 3 4 in 832 mm F 44 1 4 in 1124 mm G 13 82 in 10 mm Dia Weight 590 Ib 267 kg Lifting Eye Weight Rating 1280 Ib 580 kg Engine End G tip 4 Holes 800 426 A Do not exceed tilt angles or engine could be damaged or unit could tip A Do not move or operate unit where it could 803 983 OM 4430 Page 13 I A complete Parts List is available at www MillerWelds com 4 4 Dimensions For Units With Optional Running Gear
59. il achev assurez vous qu il ne reste aucune tra ce d tincelles incandescentes ni de flammes Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter OM 4430 Page 7 e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affec l ouie e Porter des protections approuv s pour les ore les si le niveau sonore est trop lev LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du ga sous haute pression Si une bouteille est endomme g e elle peut exploser Du fait que les bouteilles de gaz for normalement partie du proc d de soudage les manipuler ave pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les
60. in formation hourmeter or oil change count down sa m O AMPERAGE CC CV DC Welder 5 500 Watt Generator MADE IN B aa o APPLETON WI WP YAA Meter Weld Functions In Wire mode Volt meter displays preset weld voltage when not welding Meters display actual voltage and amperage when welding and for five sec onds after welding has stopped In Stick and TIG modes Voltmeter reads ON and Ammeter displays preset amperage when not welding Meters display actual volt age and amperage when welding and for five seconds after welding has stopped Meter Engine Maintenance Functions Meters display engine hours when Engine Control switch is in the Run Idle 3600 2400 position but engine is not running Meter Oil Change Countdown With en gine off place Engine Control switch in Run Idle 3000 1800 position to see hours before next recommended oil change Oil change hours start at 100 fresh oil and count down to O oil change due The meters display negative hours if 100 hours is exceeded After changing oil reset counter by cycling Engine Control switch between Run Idle positions three times Place Engine Control switch in Off position after reading meters GENERA7qR LOCK 18 PM 8 SPEED CONTROL WELD OFF RUN IDLE 3600 2400 RPM RUN IDLE 3000 1800 RPM START IN CHOKE Ref 216 172 D 5 Fuel Level Indicator With Engine running or Engine Control switc
61. ing Watts Hand Drill 1 4 in 350 350 3 8 in 400 400 1 2 in 600 600 Circular Saw 6 1 2 in 500 500 7 1 4 in 900 900 8 1 4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6 in 1720 720 8 in 3900 1400 10in 5200 1600 Air Compressor 1 2 HP 3000 1000 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 Floor Polisher 3 4 HP 16 in 4500 1400 1HP 20 in 6100 1600 High Pressure Washer 1 2 HP 3150 950 3 4 HP 4500 1400 1HP 6100 1600 55 gal Drum Mixer 1 4 HP 1900 700 Wet amp Dry Vac 1 7 HP 900 900 2 1 2 HP 1300 1300 OM 4430 Page 47 11 8 Power Required To Start Motor Single Phase Induction Motor Starting Requirements Motor Start G H J K L M N P Code KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 1 Motor Start Code 2 Running Amperage 3 Motor HP x AC MOTOR 2 4 Motor Voltage fivouts_2s0 AMPS 254 lee CODE M Hz 60 To find starting amperage N HP 1 4 PHASE 1 Step 1 Find code and use table to find kVA HP If code is not listed mu
62. itor Start Induction Run 1 3 HP 2020 720 1 2 HP 3075 975 3 4 HP 4500 1400 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5 HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 11 6 Approximate Power Requ irements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1HP 6100 1600 1 1 2 HP 8200 2200 2HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 8 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 4430 Page 46 11 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Runn
63. l level often and do not use the oil pressure shutdown system to monitor oil level Fuel Add fresh fuel before starting engine the first time see maintenance label for specifications Always leave filler neck empty to allow room for expan sion Check fuel level on a cold engine before use each day To check fuel level turn Engine Control switch to either Run ldle position LED s indicate fuel level in tank Cil EF Do not exceed the Full mark on the oil level dipstick The fuel pump may operate erratically if crankcase is overfilled Check oil with unit on level surface If oil is not up to full mark on dipstick add oil see maintenance label Use front panel meters to determine hours until next recommended oil change see Section 6 1 To improve cold weather starting Keep battery in good condition Store battery in warm area Use correct grade oil for cold weather 803 983 A Ref 216 172 D OM 4430 Page 19 I A complete Parts List is available at www MillerWelds com 5 3 Connecting Or Replacing The Battery A Connect negative cable last j SLi Fe Replacing The Battery I Remove end panel to replace battery A Connect negative cable last Tools Needed It 3 8 1 2 in 803 847 803 849 Ref S 0756 D Ref 216 172 D Ref 803 983 A OM 4430 Page 20 I A complete Parts List is available at www MillerWelds com 5
64. l y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation LAW 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org
65. lable at www MillerWelds com SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 60 Hz Generator Power Receptacles And Supplementary Protectors 120 240V N CB1 25 A MAIN BREAKER Sh ON OFF AcB2 LN Q AS Ms z q or a Bo si o X O n Z z B See Section k Es 7 2 for RC3 ui em information z a D 3 a 0Hz 420V MAIN BREAKER Controlling Engine Speed And Weld Generator Power Output c3 Generator Power Weld Speed At 3000 rpm Output Available Only At 2 4 kW kVA 60 120 Hz AC Receptacle RC3 Engine Controls Output Weld Output Engine Speed Either H Run ldle O cie position 1800 rpm Tr Power Speed Welding Not Ls Continuous Recommended E 5 kW kVA Total From All AC Receptacles No Load 2400 rpm Idle Speed pie e ps Eee 2 4 KWIKVA at 60 120 veld Speed Hz From AC Receptacle RC3 Only e Y No E e 5 KW KVA Total From All AC Receptacles 3000 rpm Load 3000 rpm At 1800 rpm 20 220A A If unit does not have GFCI re ceptacles use GFCI protected extension cord NOTICE Disconnect equipment from auxiliary power receptacles dur ing start up and shutdown Some equipment can be damaged by changes in frequency as engine rpms change during start
66. lean and tight Remove excessive coils from weld cables Use dry properly stored electrodes Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 and PC2 No remote fine amperage control Check and tighten connections to Remote receptacle RC4 see Section 5 7 No front panel voltage amperage con trol Disconnect remote control from Remote Receptacle RC4 if not needed for weld process see Section 6 8 No 24 volt ac output at Remote receptacle RC4 Reset supplementary protector CB4 see Section 8 6 No 115 volt ac output at Remote receptacle RC4 Reset supplementary protector CB3 see Section 7 2 OM 4430 Page 38 I A complete Parts List is available at www MillerWelds com Trouble Remedy Lack of high frequency difficulty in establishing Gas Tungsten Arc Weld ing arc Use proper size tungsten for welding amperage Reduce leakage of high frequency from torch or work cable check grounding remove excessive coils from weld cables use shorter weld cables etc Check cables and torch for cracked or deteriorated insulation or bad connections Repair or replace necessary parts Wandering arc poor control of arc direction Reduce gas flow rate Select proper size tungsten Properly prepare tungsten Tungsten electrode oxidizing and not remaining bright after conclusion of weld Shield weld zone from d
67. lly Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protective clothing when working on a battery e Stop engine before disconnecting or connect ing battery cables or servicing battery Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles O
68. ltiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the motors running amperage KVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 KVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes S 0624 11 9 How Much Power Can Generator Supply 1 Limit Load To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5Second Rule If motor does not start within 5 seconds turn off power to prevent motor damage Motor requires more power than generator can supply Ref ST 800 396 A S 0625 OM 4430 Page 48 11 10 Typical Connections To Supply Standby Power Utility Electrical Service Transfer Switch Essential Loads Fused Disconnect Switch If Required Welding Generator Output A Have only qualified persons perform these connections according to all applicable codes and safety practices A Properly install and ground this equipment according to its Owner s Manual and na tional
69. nected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverters after stop ping engine e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding OM 4430 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventil
70. ol switch in the Run position until unit has been in operation and loaded for a peri od of time During operation in severe cold weath er engine starts and goes to idle but stalls after a few minutes Install engine manufacturer s kit for cold weather operation OM 4430 Page 40 I A complete Parts List is available at www MillerWelds com SECTION 9 PARTS LIST 9 1 Recommended Spare Parts Dia Part Mkgs No Description Quantity Recommended Spare Parts hdc F6 021718 Fuse Mintr GI 30 Amp 32 Volt 1 Curr 215984 Filter Fuel In line 250 Kohler 1 Dre tu SAGI Gaia Parta Ge 230015 Tune up amp Filter Kit Kohler Includes 1 DE 230016 Air Filter Element Kohler d Jugo vr eau ay EAE 066698 Oil Filter Kohler 1 aa 215985 Filter Fuel w Clamps amp 1 4 in Fuel Line 1 aa e 067007 Spark Plug oras ica a ii Se gen 2 ai Pa ambiante ARA 230017 Air Filter Wrapper http www millerwelds com service replacementparts html Choose Genuine Select to review spare parts requirements such as filters spark plugs and fuses Choose Service Parts to download complete part
71. ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon 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 e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chau des e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement S il est endommag un c ble d nud peut provoquer une lectro cution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi
72. ower receptacles during start up and shutdown Some equipment can be damaged by changes in frequency as engine rpms change during start up and shutdown Ref 216 172 D OM 4430 Page 26 6 5 Process Switch I A complete Parts List is available at www MillerWelds com 1 Process Switch A Weld output terminals are energized when Process switch is in an Elec trode Hot position and the engine is running The unit will not return to idle speed when Process switch is in a Wire or TIG position and the remote contactor is on closure between pins A and B on re mote receptacle Use switch to select weld process see table below and Section 5 7 Wire Position Use Wire position for MIG welding using a voltage sensing wire feeder Stick Positions Use Stick positions for stick SMAW and air carbon arc CAC A cutting and gouging When switch is in a Stick mode select one of four dig settings to provide additional am perage during short arc length conditions and help prevent electrodes from sticking See Stick position descriptions following reading L to R Soft Arc E 7018 Position 1 This setting provides a low dig arc force setting for smooth weld performance A stable weld puddle with little arc snap gives excellent weld bead appearance with minimal spatter Medium Soft Arc Position 2 This setting pro
73. r e Sile moteur est chaud et que le liquide doit tre v rifi op rer com me suivant e Mettre des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur e D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon L utilisation d un groupe autonome l int rieur PEUT VOUS TUER EN QUELQUES MINUTES e Les fum es d un groupe autonome contient du monoxyde de carbone C est un poison invisi ble et inodore e JAMAIS utiliser dans une maison ou garage m me avec les portes et fen tres ouvertes e Uniquementutiliser PEXTERIEUR loin des portes fen tres et bouches a ration L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU e Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau 2 4 Dangers li s l air comprim RESPIRER L AIR COMPRIM peut pro voquer des blessures graves ou causer la mort e Ne pas utiliser l air comprim pour respirer e Utiliser l air comprim seulement pour le cou page gougeage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit approuv es e Ne pas diriger le jet d air vers d autres ou Soi m me L AIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo quer des blessures e Rel cher la pression d air de l outillage ou du
74. r des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipementcommand par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 metres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 6 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants A Les batteries les bornes et autres accessoires contiennent du plom
75. rafts Increase postflow time Check and tighten all gas fittings Properly prepare tungsten B 60 Hz Generator Power Receptacles RC1 And RC2 Trouble Remedy No power output at 60 Hz ac recep tacles RC1 or RC2 Reset supplementary protectors CB1 and or CB2 see Section 7 1 Stop welding or place Speed Control switch in Generator Lock position to run engine at 1800 rpm 60 Hz receptacles RC1 and RC2 work only at 1800 rpm Check receptacle wiring and connections Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 and PC2 Low power output at 60 Hz ac recep tacles RC1 or RC2 Check and clean air cleaner as necessary Check engine electronic governor system See engine manual High power output at 60 Hz ac recep tacles RC1 or RC2 Check engine electronic governor system See engine manual Erratic power output at 60 Hz ac receptacles RC1 or RC2 Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 PC2 and PC7 Check receptacle wiring and connections Check governor according to engine manual C Variable Frequency Generator Power Receptacle RC3 Trouble Remedy No generator power output at ac re ceptacle RC3 Reset supplementary protector CB4 see Section 7 2 Check receptacle RC3 for continuity and proper connections Replace receptacle if necessary
76. rc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 4430 Page 11 I A complete Parts List is available at www MillerWelds com SECTION 3 DEFINITIONS 3 1 Symbol Definitions E Stop Engine gt Run te USE o as lt gt Slow Idle ig Start Engine amp Panel Local Temperature E Fuel p DEE Engine Oil x Engine Choke su Battery Engine DA Engine A ROA PEROS A Amperes V Volts P H ix We Kei A LO Stick SMAW E fF TIG GTAW S Circuit Protector Positive Negative NU pas id gt Output O Hh s c Q wm KN EN d jid ZP SE Y E Work Connection CC oe olo Wire Feed SN P i li Electrode Negative CV Ee Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4430 Page 12 I A complete Parts List is available at www MillerWelds com SECTION 4 SPECIFICATIONS 4 1 Description This multiprocess engine driven welder and AC generator provides low speed generator AC power and DC weld out put for quiet fuel efficient operation At 1800 rpm this unit produces 5 kW kVA 60 Hz 120 240 Volt AC generator power Achieve high quality Stick and TIG welding results at either 3000 or 3600 rpm A spec
77. ructions below for necessary actions to avoid the hazards e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not con
78. s e Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire e Do not let engine exhaust sparks cause fire e Use approved engine exhaust spark arrestor in required areas see applicable codes a TRAPPED AIR PRESSURE AND WHIPPING RY HOSES can cause injury e Release air pressure from tools and system be fore servicing adding or changing attach ments or opening compressor oil drain or oil fill cap OM 4430 Page 3 HOT METAL from air arc cutting and gouging can cause fire or explosion Lh e Do not cut or gouge near flammables e Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury e Do not touch hot compressor or air system parts e Let system cool down before touching or ser vicing READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit Stop engine and release air pressure before servicing Use only genuine replacement parts from the manufacturer 1 5 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit and properly installed accessories only NOT gas cylinders Do not e
79. s as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended OM 4430 Page 5 SECTION 2 CONSIGNES DE SECURITE LIRE AVANT UTILISATION rom 2007 04fre A Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud Signification des symboles 2 1 DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin
80. s listing ENS PP aut e Finding the right parts and Download Owner s consumables has never Manuals for complete been easier parts listing OM 4430 Page 41 SECTION 10 ELECTRICAL DIAGRAMS S2 POSITION MODE 52 Ka lt gt 1 S RUN IDLE P 3600 2400 RPM HZ gt 7 2 S RUN IDLE 41 3000 1800 RPM 3 START 41 lt lt RC24 14 PCI 41 KRC24 13 POWER PCB 2 lt RC24 3 22 X RC24 2 ze d KRC24 9 REENEN 46 45 43 4 52 lt RC24 6 RCS A A RC5 6 5 3 1 4 2 PLGS PLGS 5 4 85 5 Dope A PLGS A PLG5 A PLG5 APLG5 A PLCS PLCS 8558088838238 NO ge PRESSURE me RED FED V Y Y Y V AY Y Y o GS1 RD m 35 ELECTRONIC or e u FEED SESE GOVERNOR 8 79 I RED Je UY y 12 VOLT i i STARTER I RED 1 I a I u a ELECTRIC NS ata stata a S Dt SS NS NN N 1 1 A JAJA PAPA ALTERNATOR STATOR BLACK Y 69 JL C15 9 A AA A A A AA VOLT b da POWER Q 68 TIIT REG i lt lt RC15 8 o o DD E I OPTION WELD O S4 40 KRC15 4 E SS SN SS RE n th Zeng 3 FUEL LEVEL SE SENDING mis GAS KOH
81. syst me avant d effectuer la maintenance avant de changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile LA CHALEUR DU MOTEUR peut pro voquer un incendie e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES ETINCELLES A L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion Ne pas couper ou gouger proximit de pro duits inflammables e Surveillez et garder un extincteur proximit DES PIECES CHAUDES peuvent provo quer des br lures et blessures e Ne pas toucher le compresseur ou d autres l ments du circuit air comprim chauds Laisser l ensemble se refroidir avant de toucher ou d effectuer la maintenance LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil Arr ter le moteur et rel cher la pression avant d effectuer la maintenance e N utiliser que les pi ces de rechange recommand es par le constructeur 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU
82. t de d brancher ou de brancher les c bles de batterie e Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie e Ne pas utiliser le poste de soudage pour charger les batteries ou des v hicules de d marrage rapide e Observer la polarit correcte et sur les batteries e D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion e Arr ter le moteur avant de v rifier le niveau de carburant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une source d tincelles ou d une flamme nue e Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer toul carburant renvers avant de faire d marrer le moteur Jeter les chiffons dans un r cipient ignifuge Toujours garder le pistolet en contact avec le r servoir lors du remplissage DES ORGANES MOBILES peuvent pro voquer des blessures Y e Ne pas approcher les mains des ventilateurs courroies et autres pi ces en mouvement e Maintenirferm s et fixement en place les portes panneaux re couvrements et dispositifs de protection Arr ter le moteur avant d installer ou brancher l appareil OM 4430 Page 8 e Seules des personnes qualifi es sont autoris es enlever les por tes panneaux recouvrements ou disposi
83. tated in electrical codes A Ground generator to system earth ground if supplying power to a premises home shop farm wiring system A Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators ST 800 576 B 11 4 How Much Power Does Equipment Require 60 VOLTS 115 AMPS 4 5 Hz 60 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 11 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run ning power requirement in watts 4 5Ax115V 2 520W The load applied by the drill is 520 watts Example 2 If three 200 watt flood lamps are used with the drill from Ex ample 1 add the individual loads to calculate total load 3 x 200W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts S 0623 OM 4430 Page 45 11 5 Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1 8 HP 800 300 1 6 HP 1225 500 1 4 HP 1600 600 1 3 HP 2100 700 1 2 HP 3175 875 Capac
84. ter Regulators No Labor HFUnits Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Batteries 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused b
85. tifs de protection pour effectuer s il y a lieu des travaux d entretien et de d pannage e Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le c ble n gatif de batterie de la borne e Ne pas approcher les mains cheveux v tements laches et outils des organes mobiles Remettre en place les panneaux ou les dispositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur e Bloquerle volant moteur pour viter sa rotation lors d une interven tion sur le g n rateur DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chau des e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e l est pr f rable de v rifier le liquide de refroi dissement une fois le moteur refroidi pour viter de se br ler e Toujours v rifier le niveau de liquide de refroidissement dans le vase d expansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteu
86. tion ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures oi m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respirateur d adduction d air homologu LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux e sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes
87. ts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death e Do not use compressed air for breathing e Use only for cutting gouging and tools COMPRESSED AIR can cause injury e Wear approved safety goggles e Do not direct air stream toward self or others STEAM AND HOT COOLANT can burn e f possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual e Ifthe engine is warm checking is needed and there is no over flow tank follow the next two statements e Wear safety glasses and gloves and put a rag over radiator cap e Turn cap slightly and let pressure escape slowly before completely removing cap Using a generator indoors CAN KILL YOU IN MINUTES e Generator exhaust contains carbon monoxide This is a poison you cannot see or smell e NEVER use inside a home or garage EVEN IF doors and windows are open e Only use OUTSIDE and far away from windows doors and vents BATTERY ACID can BURN SKIN and EYES e Do not tip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammable
88. tuation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 7 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away U e ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equip ment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough
89. ue dans les zones humides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil tilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et chafaudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste OM 4430 Page 6 Indique des instructions sp cifiques AEN Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3 un poste souder manuel AC avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas tra vailler seul e Couper l alimentation
90. uick business and easy With Miller you can count on years NII 00012000 of reliable service with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in the U S A ta be registered to exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related eguipment For information on other guality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage ee ep rA EX DORA ones 1 2 Arc Welding Hazards 1 3 CEngine Hazards uoces each e me oen RR S e RR RU ROS UR 1 4 Compressed Air Hazards Ve em mm AER Ron as M Fa plane Ee ont ed NEE RUE ex 1 5 Additional Symbols For Installation Operation And Maintenance 1 6 California Proposition 65 Warnings 1 7 Principal S
91. up and shut down gt Weld output and 60 Hz generator power output at receptacles RC1 and RC2 are not always available at the same time When welding generator power is available from AC receptacle RC3 only see Section 7 2 Generator power is available at receptacles RC1 and RC2 only at 1800 rpm If generator is not locked at 1800 rpm engine speed increases in response to weld load and generator power output stops at receptacles RC1 and RC2 Generator power load does not affect engine speed 1 240V 50A AC Receptacle RC1 RC1 supplies 60 Hz single phase power at 1800 rpm Maximum output is 5 KVA KW 20 A at 240 volts ac For 60 Hz generator power at RC1 set controls as shown in table 2 120V 20A AC Duplex Receptacle RC2 RC2 supplies 60 Hz single phase power at 1800 rpm Maximum output from RC2 is 2 4 KVA KW 20 A at 120 volts ac 3 Supplementary Protector CB1 CB1 protects receptacles RC1 and RC2 from overload If CB1 opens the receptacles do not work Place switch in On position to reset 4 Supplementary Protector CB2 CB2 protects RC2 from overload If CB2 opens the receptacle does not work Press button to reset If supplementary protector con tinues to open contact Factory Authorized Service Agent Combined output of all receptacles limited to 5 KVA KW continuous rating of the generator EXAMPLE If 10 A is drawn from 120 V duplex receptacle RC2 only 16 A is available at 240 V recept
92. venablement le poste sur la remor que comme indiqu dans le manuel s y rappor tant LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N utiliser que les pi ces de rechange recom mand es par le constructeur e Effectuer la maintenance et le service du moteur et du compres seur d air suivant les instructions dans ce manuel ou le manuel du moteur compresseur si applicable y El UNE REMORQUE QUI BASCULE peut LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation e L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une dis tance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoque
93. verheating sticking or getting contaminated Application Lift Arc is used for the DCEN GTAW process when HF Start method is not permitted Do NOT Strike Like A Match OM 4430 Page 28 I A complete Parts List is available at www MillerWelds com 6 8 Remote Voltage Amperage Control I D 1 Remote Receptacle RC4 EX Connect optional remote voltage amperage V A control to RC4 see Section 5 7 With remote control connected weld output in a CC mode Stick TIG is determined by a combination of front panel and remote control voltage amperage settings In CV mode Wire weld output is controlled through remote control only 2 Remote Hand Control Optional 3 Remote Foot Control Optional 00000 Engine runs at weld power speed in Wire and TIG mode whenever a device connected to the remote receptacle makes closure between pins A and B This unit does not have remote contactor control Output is al Ways on In Example Process Stick Using Remote On Off Min 20 A CC DC Max 160 A CC DC 2 Max 160 A DC Z REMOTE Min 20 A DC Set V A Control Adjust Remote V A Control Connect Remote gt Set Process gt Mid Range About 160 A gt Stick Welding Only V A Control To Remote Receptacle RC4 803 984 A 216 172 D S 0769 S 0774 OM 4430 Page 29 I A complete Parts List is avai
94. vides a low to medium dig arc force that gives a slightly more fluid weld puddle more arc snap and reduces the potential for electrode sticking at shorter arc lengths Medium Stiff Arc Position 3 This setting provides medium dig arc force for open root vertical up joints or joints that do not require additional current for fit up inconsistencies Stiff Arc E6010 Position 4 This setting provides a high dig arc force for open root vertical down joints where additional current is needed to compensate for tight joint fit up without the need to increase overall welding current This setting is rec ommendedfor those who prefer a very stiff arc with 6010 electrodes The dig circuit is disabled when switch is in Wire or TIG positions TIG Position Electrode Hot Lift Arc Scratch Start TIG Provides great DC starts with either start ing method With switch in this position normal open circuit voltage is not present between the electrode and workpiece A solid state contactor energizes after the electrode touches the workpiece preventing overheating sticking or con tamination of the electrode see Sections 6 6 and 6 7 Ref 216 172 D 803 984 Process Switch Settings Switch Setting Process Output On Off Control Electrode Hot Wire MIG GMAW Electrode Hot Stick SMAW Electrode Hot Stick Air Carbon Arc CAC A Cutting And Gouging Electrode Hot Electrode Hot Scratch
95. xceed maximum lift eye weight rating see Specifications e Liftand support unit only with proper equipment and correct procedures e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable L3 FLYING SPARKS can cause injury e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away N MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls 3 OM 4430 Page 4 WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body pn K other people or any metal when threading welding wire OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit pa STATIC ESD can damage PC boards e Puton grounded wrist strap BEFORE handling So e boar

Miller Electric 280 NT Welding System User Manual

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