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Miller Electric 251 NT Welding System User Manual

1. 7 14202 lt spiace add 1982 935 HOLD DOWN Dattery ae ss une en a a a din 1 m EEN 1182 897 DOOR 366655 Dal ns amine nt nan cac ue Min dece qoa eee 1 mp EEN 168 385 LABEL warning battery explosion can blind nanan 1 oH aues pane 167 731 CABLE bat pos 19 500 Ig included w engine 1 BE DEEN Batt 167677 BATTERY stor 12V 450crk 75rsv GP58 1 EU MDC 2102 045 se BASE xe td Soest ce ee ot Se dut eite us 1 DO two sels to iai lol 057 hx COVER DASO 1 daba uct eost EEN 4 33 DCZ 187 018 STABILIZER ASSEMBLY consisting of 1 OTHERS 187 020 STABILIZER aci iio 34 SR1 183051 ols D 182 928 T rc 159 905 cr 121 652 No DR EE 174 001 e ia ddl eati ie toit 182 079 Suid acce sett 124 253 24 EESE rU 187 502 error tod 182 922 PO A ET E 182 925 HO anos 181 587 41 PC2 198412 OM 486 Page 40 180 625 164 920 RECTIFIER si 3ph 300A BRACKET mtg generator BRACKET mtg engine FILTER KIT fuel w clamps SEAL fuel hose fitting BRACKET mtg rectifier BRACKET mig stab reactor TANK fuel 10 gal consisting of BUSHING tank fuel FITTING stand pipe BUSHING fuel tank 1 210 ID GAUGE fuel TRAY pc board CIRCUIT CARD ASSEMBLY field current controller Item Dia Par NO Mkgs N
2. Combined output of all receptacles limited to 8 kVA kW rating of the TOTAL ALL LOADS 8 000 WATTS generator CN fe AN GFCI Receptacle Option E 1 120 V 15 A AC GFCI Recep 240V 120v 120VZ tacles GFCI2 and GFCI3 GFCI2 and GFCI3 supply 60 Hz single phase power at weld power speed Maximum output from GFCI2 or GFCIS3 is 2 4 KVA KW Cir cuit breaker protection is the same as standard receptacles If a ground fault is detected the GFCI Reset button pops out and the circuit opens to disconnect the faulty equipment Check for damaged tools cords plugs etc connected to the receptacle Press button to reset receptacle and resume operation At least once a month run engine at weld power speed and press Test button to verify Simultaneous Welding And Auxiliary Power GFCI is working properly Output 120 V 240 V Receptacle Receptacle Amperes Amperes Weld Current Amperes Ref ST 189 925 A OM 486 Page 21 SECTION 7 MAINTENANCE AND TROUBLESHOOTING Routine Maintenance ES A Stop engine before maintaining 7 See Engine Manual and Maintenance Label Ser pure vice more often if used in severe conditions fluids To be done by Factory Authorized Service Agent 8h Check fluid levels Wipe up spills See Section 4 2 OIL Full Check and clean Service air filter wrapper spark arrestor screen foam element See See Section 7 4 Section 7 3 50h C
3. L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Laisser l quipement refroidir respecter le facteur 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 ELECTROSTATIQUES 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 UNE REMORQUE QUI BASCULE peut entrainer des blessures e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remorque comme indiqu dans le manuel s y rapportant LIRE LES INSTRUCTIONS e Utiliser seulement les pi ces de rechange d origine e Effecteur la maintenance et la mise en service d apr s le manuel et celui du moteur OM 486 Page 7 LE RAYONNEMENT HAUTE FR QUENCE H E risque de provoquer des interf rences e le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipements de radio navigation et de communication 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 installation e L utilisateur est tenu de faire corriger rapidement par un lectrici
4. 4 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI re ceptacles use GFCI protected extension cord install 12 99 Ref ST 800 652 Ref ST 800 477 A ST 158 936 A S 0854 level often and do not use the oil pres sure shutdown system to monitor oil level 1 Fuel Add fresh fuel before starting engine the first time see maintenance label for specifi cations Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Check fuel level on a cold engine before use each day Ref ST 151 983 ST 801 942 C Ref ST 800 395 2 Oil After fueling check oil with unit on level sur face If oil is not up to full mark on dipstick add oil see maintenance label CS To improve cold weather starting Keep battery in good condition Store battery in warm area off concrete surface Use correct grade oil for cold weather OM 486 Page 13 5 A For 30 Minutes OR 30 A For 12 Minutes OM 486 Page 14 Remove battery from unit 1 Eye Protection Safety Glasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte 1 265 Specific Gravity 5 Well Fill each cell with electrolyte to bottom of well maximum Do not overfill battery cells Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 6 Battery Charger A Read and follow all instru
5. United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com Miller The Power of Blue
6. 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 Ifunit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG EE 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 31 Conductor size is based on maximum 296 voltage drop OM 486 Page 38 SECTION 10 PARTS LIST Y 4 y A m o ICS Hardware is common and not available unless listed 54 Fig 10 2 Q ST 802 048 D Figure 10 1 Main Assembly OM 486 Page 39 Item Dia Part NO Mkgs NO Description Quantity Figure 10 1 Main Assembly T ETE PPS 182 907 ss PANEL TI
7. Find code and use table to find KVA HP If code is not listed multiply 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 Single Phase Induction Motor Starting Requirements motor s running amperage Motor Start E S P kVA HP x HP x 1000 VOLTS EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Volts 230 HP 1 4 Using Table Code M results in KVA HP 11 2 STARTING AMPERAGE 11 2 x 1 4 x 1000 230 122A Starting the motor requires 12 2 amperes 9 9 How Much Power Can Generator Supply 1 LimitLoad 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 486 Page 36 9 10 Typical Connections To Supply Standby Power 7 Customer supplied equipment is required if generator is to supply standby power during emergencies or power outages 1 240 V 120 240 Volt Fate oo me Nem a T Service a 120 V 2 7 amp Si O Z 120 240 Volt Single Phase Three Wire Generator Output Connection Ground 1 Power C
8. 2 Dimensions Weights and Operating Angles Ak Dimensions A Height 33 in 838 mm Width 18 3 4 in 476 mm Do not exceed tilt angles or engine could Depth 45 1 2 in 1156 mm D be damaged or unit could tip A 18 in 457 mm G A de not move or operate unit where it could 4 Holes Ip B 16 1 2 in 419 mm C 3 4 in 19 mm E F D 3 1 8 in 79 mm 25 E 32 3 4 in 832 mm 259 25 F 45 1 2 in 1156 mm SS 259 NOS G 13 32 in 10 mm Dia Weight 615 lb 279 kg Engine End ST 800 426 3 3 Fuel Consumption o N o C LITERS HR amp o IMP GAL HR D 2 8 U S GAL HR DC CC STICK DC CV MIG AUX POWER IDLE 2200 R P M 100 150 200 250 300 350 400 1450 500 DC WELD AMPERES AT 100 DUTY CYCLE AAA 0 1 2 3 4 5 6 7 8 9 10 POWER KVA AT 100 DUTY CYCLE ST 189 264 OM 486 Page 10 3 4 Auxiliary Power Curve The ac auxiliary power curve shows the auxiliary power available in amperes at the receptacles N Er O gt oc H O s O st 40 60 80 100 120 AC POWER AMPERES AT 120V 20 30 40 50 60 AC POWER AMPERES AT 240V ST 189 268 3 5 Duty Cycle Duty cycle is the percentage of 10 100 Duty Cycle at 250 Amperes DC minutes that unit can weld at rated load without overheating A Exceeding duty cycle can damage unit and void warranty Continuous Welding H T A8 T a C a zl T z DUTY CYCLE ST 182
9. 298 OM 486 Page 11 3 6 Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage A CC DC Mode and amperage output capabilities of i the welding generator Curves of other settings fall between the i curves shown 70 60 50 40 DC VOLTS 30 20 100 150 200 250 300 350 O C CH DC AMPERES B CV DC Mode 50 40 30 20 DC VOLTS 10 0 BEN 0 100 200 300 400 500 600 DC AMPERES C CC AC Mode 80 70 60 50 40 AC VOLTS 30 20 10 100 150 200 250 300 350 O C CH AC AMPERES ST 189 266 ST 189 267 ST 189 265 OM 486 Page 12 4 1 SECTION 4 INSTALLATION Movement A Do not lift unit from end Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil EF Follow run in procedure in engine manual CS This unit has a low oil pressure shut down switch However some condi tions may cause engine damage be fore the engine shuts down Check oil Installing Welding Generator Airflow Clearance Electrically bond genera tor frame to vehicle frame by metal to metal contact A Do not weld on base Weld ing on base can cause fuel tank fire or explosion Bolt unit down using holes pro vided in base Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal
10. 925 A 7 5 Changing Engine Oil Oil Filter And Fuel Filter A Stop engine and let cool 1 Oil Drain Valve 2 1 2 1Dx 12 in Hose 3 Oil Filter Change engine oil and filter accord ing to engine manual A Close valve and valve cap before adding oil and run ning engine Fill crankcase with new oil to full mark on dipstick See Section 7 2 4 Fuel Filter 5 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 gt Ref ST 801 942 C ST 800 395 B Ref ST 189 925 A S 0842 OM 486 Page 25 7 6 Adjusting Engine Speed 2200 100 rpm 3700 50 rpm IR 5 Left Side Top View Tools Needed gt EY J E 1 4 3 8 in OM 486 Page 26 After tuning engine check engine speeds with a tachometer see table If necessary adjust speeds as follows Start engine and run until warm Turn A V control to max Idle Speed Adjustment 1 Throttle Solenoid 2 Mounting Screw Loosen two mounting screws 3 Governor Arm 4 Carburetor 5 Idle Speed Screw Pull governor arm away from carburetor and hold while making the following adjustment Turn idle speed screw until engine runs at idle speed see table Release governor arm Place Engine Control switch in Run Idle position 6 Carburetor Stop Wit
11. Check and adjust engine speed see Section 7 6 Check for obstructed movement of solenoid linkage see Section 7 6 Have Factory Authorized Service Agent check field current control board PC2 Weld output cannot be adjusted Check position of Remote Amperage Voltage switch see Section 5 1 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 Check and secure lead connections to A V control Be sure connection to work piece is clean and tight Remove excessive coils from weld cables Use dry properly stored electrodes Check and adjust engine speed see Section 7 6 Have Factory Authorized Service Agent check brushes slip rings and field current control board PC2 Remote contactor control does not activate contactor Place Output Contactor switch in Remote 14 position see Section 5 1 Check and tighten connections to Remote 14 receptacle RC1 see Section 4 8 No power output at Remote 14 receptacle RC1 Reset circuit breaker CB1 and or CB2 see Section 7 7 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
12. MILLER 066 113 Onan 149 2206 01 Gasoline Fram G10E1 Air Filter Service 100 hours or less see Owner s Manual Air Filter Element MILLER 064 617 Onan 140 2628 01 Air Filter Wrapper MILLER 065 653 Onan 140 1496 12 Volt Battery BCI Group 58 Cranking Performance at 0 F 18 C 430 Amps min Val Col Engine RPM No Load alve C icis Cold Weld Ins 0 005 in 0 13 mm Idle If using LP fuel system check valve clearance at 50 hours every 200 hours thereafter Spark Plug Gap 0 025 in 0 6 mm Spark Plug Champion RS17YX Preferred or RS14YC Use only resistor spark plugs and wires Spark Arrestor Inspection and Service 20 operating hours see Owner s Manual 165 623 G OM 486 Page 23 7 3 Servicing Air Cleaner Stop engine Do not run engine without air cleaner or with dirty element 1 Wrapper Foam Element or gt Wash wrapper with soap and water U 0 solution Allow wrapper to air dry a cU completely y R N D ai Spread 1 tablespoon SAE 30 oil START OE evenly into wrapper Squeeze out excess oil 2 Element Replace element if damaged dirty or oily aircleaner3 1 97 ST 156 852 Ref ST 185 095 A S 0759 A Stop engine and let cool 1 Spark Arrestor Screen Clean and inspect screen Replace spark arrestor if screen wires are broken or missing Tools Needed 4Q 1 4 in _ LL OM 486 Page 24 ST 801 942 C Ref ST 801 695 A Ref ST 189
13. N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 1 6 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 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 OM 486 Page 4 ARC WELDING can cau
14. 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 3 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 486 Page 34 9 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running 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 10 in 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 1 HP 20 in 6100 1600 High Pressure Washer 1 2 HP 3150 950 3 4 HP 4500 1400 1 HP 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 486 Page 35 9 8 Power Required To Start Motor Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage AC MOTOR 60 PHASE 1 Step 1
15. a Ad 2ARCZ z B d ELECTRIC FUEL BASE PANEL PUMP OPTION GROUND GROUND Eee J Figure 8 1 Circuit Diagram For Welding Generator OM 486 Page 30 120V RC3 Y wo 50 es EBI 64 33 O O 50 A 120V Y W 6 nc2 A 67 ma CB3 BJ s ce e E 33 CB1 p er S 53 Y WX G 240V A ST 53 Q SS Pa A A A EN ACER ERE ome OE PEE We ROP 1 MAIN FIELD 76 71 77 76 126 4 S 4 oom 2 41 16 8 10 3 731 st HHH Da 113151718111 1 2 O 29 70 72 75 74 725 S1 1 E 2 S1 1 ELECTRODE POS Xx 2 AC gt 3 ELECTRODE NEG 2 18 o3 k l1 77 8 O C 5 7 6 O 19 6 O 139 45 Fo to SO 62 CB4 My 33 k ABCDREF litd d o d db o 33 33 53 60 60 51 52 50 33 33 GFCI 2 64 He 60 ih gH ON ZT GND AW GFCI 2 amp pres CAE B N gt 33 GND N S NS E SS RCI Y WX o 240N GFCI RECEPTACLE PTIO ET NU DEM 1 ST 190 578 B OM 486 Page 31 SECTION 9 AUXILIARY POWER GUIDELINES 9 1 Selecting Equipment Auxiliary Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment Be sure equipment has this symbol and or wording aux pwr 2 99 Ref ST 159 730 ST 800 577 9 2 Grounding Generator To Truck Or Trailer Frame Gene
16. can cause injury e Keep away from fans belts and rotors CLS Ny 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 guards or covers for maint enance and troubleshooting as necessary e To prevent accidental starting during servicing disconnect negative battery cable from battery e Keep hands hair loose clothing and tools away from moving parts e Reinstall panels or guards and close doors 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 e Block flywheel so that it will not turn while working on generator components 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 Observe correct polarity and on batteries Disconnect negative cable first and connect it last BATTERY ACID can BURN SKIN and EYES e Do not tip battery e Replace damaged battery e Flush eyes and skin immediately with water e Use equipment outside in open well ventilated areas e f used in a
17. chaud e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r ser voirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le cable 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 che mins inconnus ventuels en provoquant des risques d lectrocution et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites gel es e En Cas de non utilisation enlever la baguette d lectrode du porte lectro de ou couper le fil la pointe de contact e 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 rever
18. en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz comprim les quipements associ s et les publication P 1 CGA num r es dans les normes de s curit 1 3 Dangers existant en relation avec le moteur LE CARBURANT MOTEUR peut pro voquer un incendie ou une explosion e Arr ter le moteur avant de v rifier le niveau de carbu rant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une sour ce 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 tout carbu rant renvers avant de faire d marrer le moteur e Jeter les chiffons dans un r cipient ignifuge OM 486 Page 6 LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de verifier le liquide de refroidissement 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 autre ment dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer comme suivant e Mett
19. gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs e 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 e Turn face away from valve outlet when opening cylinder valve e Keep protective cap in place over valve except when cylinder is in use or connected for use e Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 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 overflow 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 MOVING PARTS
20. not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 1 1 Signification des symboles oignifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives A ldentifie un message de s curit particulier Signifie NOTA n est pas relatif la s curit 1 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 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 cu rit num r es la section 1 5 Veuillez lire et respecter toutes ces normes de s curit A 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 particulierement les enfa
21. tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way Miller The Power of Blue Effective January 1 2000 Equipment with a serial number preface of LA 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 IS 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 replace 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 date that the equipment was delivered to the original retail purchaser or one
22. year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate 185 amp Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HE Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment 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 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor S
23. 0 W 200 W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts OM 486 Page 33 9 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 Capacitor 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 9 6 Approximate Power Requirements 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 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5 HP 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
24. 355 i arid dodo de Ee Rica erg dead s e t c art E 7 1 5 Principales normes de s curit iussus even qux dece bue oa Picea aie ed te 8 1 6 Information sur les champs lectromagn tiques 8 SECTION2 DEFINITIONS items est ends en saisies 9 2 15 Symbol Dernlllolis EE 9 SECTION 3 SPECIFICATIONS EE 9 3 1 Weld Power And Engine Specifications 9 3 2 Dimensions Weights and Operating Angles 10 9 94 E el Gonsumpllols i seio dm xu ex d PG E uc d xau iG das e E 10 9 4 Auxillary Power QUIVB rui oo laces Y ld UTR 11 CSSMEEBUUAG ULP 11 9 5 Woll Ampere Curves vicus asd asd ds Ryan Gd RA do danses ndis amu ia 12 SECTION 4 INSTALEATION 53 252295 L xke RR ERE E L RER ds 13 4 1 Installing Welding Generator 13 4 2 Engine Prestart Checks user Eu AA AAA rna ie ENEE AA AA CROCO 13 4 3 Activating The Dry Charge Battery If Applicable 14 4 4 GOonneciing Whe Baten S pudo apices tae as Fre dU EYE Gees YER ER ERA 15 2 5 Whstalliig Exbhaust PIDO SAS eara sua eter Paes etes vane es 15 4 6 Connecting To Weld Output Terminals esee 15 4 7 Selecting Weld Cable Gzes hh hh hh 16 4 8 Remote 14 Receptacle Information e cece eens 16 4 9 Adjusting MIG Weld Puddle Consistency 17 SECTION 5 OPERATING WELDING GENERATOR x x x x x x lt x x K K ee
25. AMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normale ment partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille a gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bou teille e Ne jamais souder une bouteille pressuris e risque d explosion 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 e Ne pas tenir la t te
26. E oil drain 3 8 18NPTF included with engine 1 ebe Ee 165 623 LABEL engine maintenance 1 ji MM EN 187 126 ENGINE gas COMSISHING KEE 1 WO ES 183 434 MUFFLER exhaust engine seran the a Rp c Ro OE D Fabi to GEO Anas 1 2 T 065 319 s e GASKET Mula id ie RERO teed UR idea ees 1 D cnius 059 926 PIN spring CS 093 x 1 000 1 22 TS1 165 810 SOLENOID 14VDG 459A reiege ele pda eere met hike pare PCs 1 26 EE 165 522 BRACKET mtg solenoid 1 REE AUEN ia 192 868 INDICATOR CAP ASSEMBLY Dipstick 1 aE det lee dc 192 869 ADAPTER ASSEMBLY 1 in collar on oil fill tube 1 EE 192 093 PUMP electric tuel PT EE ERE PLG5 CONNECTOR Part of engine harness d EET RC5 116045 CONNECTOR amp PINS eee 1 See PLG7 RC7 CONNECTOR Part of engine harness 1 PLG10 174823 CONNECTOR 8 SOCKETS 1 Rund eant RC10 174824 CONNECTOR amp PINS 1 2A DP Si T0 9 au GENERATOR ax eric det hindi tutes i dard led ned be Papa pata d Ad 1 O ENTER 167 730 CABLE battery neg 29 00 Ig 1 pao dee ds 165600 CABLE battery neg 18 50 Ig
27. ITCH toggle DPDT 15A 125VAC 1 8 PCT 184731 MODULE pull to idle 4 pin 1 9 PC4 147554 CIRCUIT CARD ASSEMBLY connector receptacle 1 sis S4 011 609 SWITCH tgl SPDT 15A 125V 1 m ees SR 011 611 SWITCH tol DPDT 15A 125V 1 12 CB5 6 083432 CIRCUIT BREAKER man reset 1P 10A 250V B co us S2 176606 SWITCH ign 4posn c e R ra Ra teen eae eebe SR 177000 e 61 e Een 61 EE 14 RC2 3 141432 RECEPTACLE str dx grd 2P3W 20A 125VAC Sew aan e GFCI2 3 147 939 RECEPTACLE str dx grd 2P3W 15A 125VAC GFCI 152 POS 148 021 CIRCUIT CARD filer lt 1 utens see mar Re Cai Dom RR 16 CB1 2 117 501 CIRCUIT BREAKER man reset 1P 40A 250V 17 CB3 4 093996 CIRCUIT BREAKER man reset 1P 20A 250V SVG 252 PCS a 148090750 CIRCUIT GARD Tillet HE siii hr RR nr Rex CR nte Sehen Ti MED 073 756 STAND OFF 6 32 x 02910 send shew eis bad hat uhi amet haie x E SM 182870 e el HRS ei E push He IEN eeneg 119014 ss LEVER Switch eler EE 099 255 TERMINAL pwr output ME Ds Anus ate Saabs 093 030 STUD brs 250 201 750 siu op erg and he Su ir aed X EI UL 010915 WASHER fat brs 250 REESEN PETRUS 601 836 NUT
28. LOAD lt 000 WATTS RC1 supplies 60 Hz single phase VA 2 power at weld power speed Maxi NEUTRE RACOORDE AL BAT mum output is 8 KVA KkW 2 120 20 A AC Duplex 120V 120v V Receptacle RC2 3 120 V 20 A AC Duplex Receptacle RC3 J 0 on RC2 and RC3 supply 60 Hz single n La J phase power at weld power speed Maximum output from RC2 or RCS is 2 4 KVA KW 0 nm 4 Circuit Breakers CB1 and CB2 CB1 and CB2 protect RC1 from over LA A 7 load If CB1 or CB2 opens RC1 and one of the 120 volt receptacles does not work 120 volts may still be pres 5 Circuit Breaker CB3 6 Circuit Breaker CB4 CB3 protects RC2 and CB4 protects 2 3 RC3 from overload If a circuit break er opens the receptacle does not work Press button to reset circuit me breaker If breaker continues to Simultaneous Welding And Auxiliary Power open contact Factory Output Authorized Service Agent 120 V 240 V Combined output of all receptacles Weld Current Receptacle Receptacle limited to 8 KVA kW rating of the gen Amperes Amperes Amperes erator EXAMPLE If 20 A is drawn from each 120 V duplex receptacle only 13 A is available at the 240 V receptacle 2 x 120 V x 20 240 V x 13 A 8 KVA KW Ref ST 189 925 A OM 486 Page 20 6 2 Optional Auxiliary Power Receptacles If unit does not have GFCI re ceptacles use GFCI protected extension cord 7 Auxiliary power decreases as weld current increases
29. NING 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 44 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The following terms are used interchangeably throughout this manual MIG GMAW Wire Welding TIG GTAW Stick SMAW TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 15154 Symbol Sag uim quema deba dtt e o sen quem de bee no ua os 1 152 Are Welding lt Te ess ai deas epa eee RE E ee 1 13 Engine Hazards sesta rn emcee EUR ERE es RON ee oe eh ES REOR UTE oa RETE ES 2 1 4 Additional Symbols For Installation Operation And Maintenance 3 155 Principal Safety Standards arias e a des A RT ud ade 4 50 EMF INOMANON rod ds Ae a we See K SEIS Seve 4 SECTION 1 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 1 1 Signification des symboles is bn er Eee s RESO ERA DE 5 1 2 Dangers relatifs au soudage l Arc scere ri RE EE REY E REI Aye das 5 1 3 Dangers existant en relation avec le moteur 6 1 4 Dangers suppl mentaires en relation avec l installation le fonctionnement etia maintenance 2 35 5 2
30. O Description Quantity Figure 10 1 Main Assembly Continued aide Ge etlech RCA 174824 CONNECTOR amp PINS NN 1 bett deg aids PLG1 174823 CONNECTOR amp SOCKETS 1 OE PLG3 135275 CONNECTOR 8 SOCKETS 7 TER PLGO An 174929 CONNECTOR amp SOCKETS serors dr ate ceteri later H DRE RC6 174824 CONNECTOR amp PINS ese n mH m mmm ss 1 T PLG9 168071 CONNECTOR 8 SOCKETS l 42 C82 176007 CAPACITOR slectl 1200uf 300VDC 1 uus es wi aaa decani 170 199 5 OLAMP Capacior auia addon d rd arca 2 T 1T 172661 BLOCK stud connection 6posn consisting of 1 TIPPS 1794945 2 JUMPER EINK 2 circio rae C as Te NC SEPTIES 172 791 HOLDER fuse mintr anida led lia 2 44464 Fly 1109296 FUSE mintr gls RE 2 47 SR2 3 035704 RECTIFIER integ 40A 800V 2 48 D2 oso 199 104 DIODE DOS irt eR dg aes MO du do E acepte eu 1 49 C1 176719 CAPACITOR electl 1000uf ZbVIDC anann 1 OI M 177196 2 0LAMPS GADSCIOE accio a ETUR Uam Donar GU om eod eom iii 1 51 CT1 187144 TRANSFORMER current sensing 1 iD va RAD wa 199 9le xi RESISTOR WW e SOW 5I acarrea 2 u c PUTEM 18062800 PANEL lower TONT vario ts b eie CE ndr t ire p
31. OM 486 187 236H February 2000 mE Miller y MIG GMAW Welding The Power of Blue Flux Cored FCAW Stick SMAW Welding PA TIG GTAW Welding di Description oa Engine Driven Welding Generator Trailblazer 251 NT Lu OWNER S MANUAL Visit our website at www MillerWelds com 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 T RU E Bl T El tradition They re just as committed to providing equipment and service 6 WARRANTY d that meets the high standards of quality and value established in 1929 Working as hard as you do This Owner s Manual is designed to help you get the most out of your every power source from Miller is backed by the most Miller products Please take time to read the Safety precautions They will hassle free warranty in the help you protect yourself against potential hazards on the worksite We ve business made installation and operation quick and easy With Miller you can count on years
32. ON SIS ege eee eee e esce 1 Ee W 185 352 PANEL right side stainless 1 zu ee eee 182 965 PANEL left SIG cure ei utor De a 1 E IER 185353 PANEL left side stainless iret ette cic etica oe os 1 MEC MO EN 185221 COVER OD s dias donat usb oum A MG dendum dias 1 COE 6 185 354 COVER top stainless 1 reu tn tomb ss et 182 761 LABEL general precautionary engine drive 1 lt n PP 192 042 LABEL warning engine Tue 1 SUP EUH CREE 181881 GROMMET neck filler 1 J me 147 601 CAP tank screw on 1 O tin 108 487 LABEL warning falling equipment etc 1 o MR ON 183 433 PIPE exhaust elbow i mte 1 Lo eM t 183 314 CLAMP muffler 1 625 dia 1 T eren 182 365 PANEL rear upper n 1 QUPD 185 351 PANEL rear upper stainless 1 ee 189 626 n BAFFLE IE onis dt tet t bom Do SD ito 1 185 323 SEAL baffle engine air 2 S 010 493 BUSHING snap in nylon e 1 o PP 1599 T4 UPRIGHT Dass uiuo aste wan cet diced RE mm IUE cr veas 1 EE 164928 42 SEAL DAM EEN 1 SPEM RES 183 166 PANEL rear lower RR RR RR RR RR RA 1 E 165 271 VALV
33. ST 801 943 B Ref ST 189 925 A OM 486 Page 15 4 7 Selecting Weld Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding Hess 100 UON QRERSS 45 m 60 m rom 90 m a 05 e a 20 e Dur cdd 60 E id Duty 10 100 Duty Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 300 1 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 350 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 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 Contact your distributor for the mm equivalent weld cable sizes S 0007 E 4 8 Remote 14 Receptacle Information Engine runs at weld power speed whenever a device connected to the remote 14 receptacle is running o 7 REMOTE 14 Socket Socket Information O EE o A 24 volts ac 24 VOLTS AC OUTPUT B Contact closure to A completes 24 volt ac contac CONTACTOR e SCT circuit Protected by circuit breaker 115 volts ac 115 VOLTS AC OUTPUT J Contact closure to completes 115 volt ac contac CONTACTOR c oo circuit Protected by circuit breaker C 0 to 10 volts dc output to remote control A V D Remote control circuit common AMPERAGE VOLTAGE E 0 to 10 volts dc input command signal from remote control G Circuit common for 24 and 115 vo
34. T e IN DAMP AREAS IF MOVE RUN MENT IS CONFINED OR IF DO NOT ROBE THERE IS A DANGER OF E G AN START SWITCH FALLING SES REQUIRED FOR IE WEEE d ING PROCESS TIG STICK WIRE TOTAL ALL LOADS 8 000 WATTS C B 10 e m e NS RATED WELD OUTPUT peu E e O CC CC CV AC DC DC X X d NT 4 NS d MAN OCH 75 80 50 VOLTS 25 25 25 240V 120V AMPERES 200 250 250 w w 1 20V DUTY CYCLE 6096 100 100 MAX RPM 3750 3750 3750 L J IDLE RPM 2200 2200 2200 O 14 14 OJO FEEDER NE m PN e OUTPUT 1 DC Polarity AC Switch A Do not switch under load Use switch to select AC weld output or polar ity of DC weld output 2 Process Select Switch A Do not switch under load Use switch to select output for weld process 3 AN Control Use control to select weld voltage or amperage Control may be adjusted while welding 4 Engine Control Switch Use switch to start engine select speed and stop engine In Run ldle position engine OM 486 Page 18 runs at idle speed at no load and weld power speed under load In Run position engine runs at weld power speed 7 Place switch in Run position to operate most GMAW equipment 5 Engine Choke Control Use control to change engine air fuel mix To Start pull out choke and turn Engine Control switch to Start position Release switch and slowly push choke in when engine starts If the engine does not start let the engine come to a complete stop before attempting rest
35. ad RE d 1 148 EE Fig 10 2 PANEL front w components nee 1 DT PETTEE EEIE 197 930 LABEL warning do not weld on base 2 mo EO x 021 718 5 FUSE mintr e EE VETERE 137046 TUNE UP amp FILTER KIT consisting of 1 ENEE 064617 ger ELEMENT air cleaner a re ae Cere ree rg cn d T 065 251 x OIL FIVER S isa ta GR taf Saca E Fees ta deett T iubeas Te 121 652 c FIETERIGEAMPS fuel aac sang ER EXE Ld b RE Oa Sesso H T 00370920 OPARK PLUG EE Optional Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor 5 ICS Hardware is common and not available unless listed ST 802 049 B Figure 10 2 Panel Front w Components OM 486 Page 41 Item Dia Part NO Mkgs NO Description Quantity Figure 10 2 Panel Front w Components Fig 10 1 Item 54 We T 197 599 4 PANEL e EE 2 49 VRI s 046 819 2 SUPPRESSOR ires etre RR or exon Cor A ane e 91 187 190 SWITCH changeover e E EE 197 199 BRACKET Shunt Mtg EEN Sp CoD E 030 080 SHUNT meter 50MV 400A Ot aque Hes 072529 POTENTIOMETER uua ited oe haan CR ate E Roi f as rm S6 088409 SW
36. art To Stop turn Engine Control switch to Off position 6 Engine Hour Meter 7 Output Contactor Switch Use switch to control remote contactor if connected to remote 14 receptacle RC1 see Section 5 2 A Weld output terminals are energized when Output Contactor switch is On and engine is running 8 Remote Amperage Voltage Switch Use switch to select front panel or remote amperage voltagecontrol see Section 5 2 Ref ST 189 925 A 5 2 Remote Amperage Voltage Control 1 Remote 14 Receptacle RC1 Connect optional remote control to RC1 see Section 4 8 2 Remote Hand Control Optional 3 Remote Foot Control Optional Engine runs at weld power speed whenever a device con nected to the remote 14 recep tacle is running In Example Process Stick SMAW Min 40 A CC DC Max 140 A CC DC ELECTRODE A POSITIVE my A AN CONTROL Max 140 A DC Ox E DO NOT SWITCH L UNDER LOAD al TIG WIRE Min 40 A DC Set Remote Control Set Polarity Switch Set Process and Adjust Remote Control owitches A N Control Stick Welding Only ST 801 943 B ST 189 925 A S 0769 S 0774 OM 486 Page 19 SECTION 6 OPERATING AUXILIARY EQUIPMENT 6 1 ER Power And Circuit Breakers lfunit does not have GFCI re ceptacles use GFCI protected extension cord CS Auxiliary power decreases as weld current increases 6 1 240 V 50 A AC Receptacle RC1 TOTAL ALL
37. brs hex jam 250 20 I 3 SE i tico adis 188 039 COVER receptacle with gasket 1 TIC T5992 WEE BELO PTE 1 28 RC1 182954 RECEPTACLE str 3P4W 50A 125 250VAC 1 ee en iod a 119 172 PLUG SEDOA 125 250WV 3 oh nie zc ah cela aces cte dere Y d Ee 170 391 CAP dust connector 9760 20 protector 1 su NEE HM 145247 METER hour 10 32VDG gett v e Rex E REN Ra S E dens 1 Eo DEE 021 385 BOOT toggle switch lever 3 mo EEN 097 924 KNOB DOINET zi sare hoo eter dens esa a B ne ER abs da t es 1 cc PEE 072 590 LOCK shaft 375 32 x 250dia shaft 1 PRECOR 115 493 HANDLE range switch 1 c mE NAMEPLATE order by model and serial number 1 Optional To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 486 Page 42 Item Par No No Description Quantity Figure 10 3 Generator Fig 10 1 Item 24 tian all apes sistat 186239 4 STATOR GEET 1 e iaa 013 367 LABEL warning moving parts can cause serious injury 1 TOR TEPORE 186 239 ROTOR ASSEMBLY consisting of 1 HAC PCR 1011148 BEARING Dal ori detached do Seer Mie di
38. c tions supplied with battery charger Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am peres Disconnect charging cables and install battery 7 When electrolyte is low add only distilled water to cells to maintain proper level Tools Needed Eo AS KE rubbergloves Sech glasses drybatt1 1 98 S 0886 4 4 Connecting The Battery Connect negative cable last e RUN IDLE 4 Tools Needed oe 3 8 1 2 in Ref ST 800 394 C Ref ST 189 925 A Ref S 0756 D 4 5 Installing Exhaust Pipe CS Point exhaust pipe in desired direction If unit is truck or trailer mounted point pipe away from direction of travel RUN IDLE RUN N START Tools Needed YT 1 2 in ST 801 681 Ref ST 189 925 A Do not connect to CC and CV terminals at the same time Work Weld Output Terminal Stick TIG CC Weld Output Terminal 3 Wire CV Weld Output Terminal For MIG welding connect work cable to Work terminal and wire feeder cable to Wire CV terminal For Stick TIG welding connect work cable to Work terminal and electrode holder cable to Stick TIG CC terminal AN ELECTRIC SHOCK CAN KILL ARCING CAN BE HAZARDOUS DO NOT CONNECT TO BOTH CC AND CV WELD OUTPUT TER STICK TIG MINALS AT THE SAME TIME BOTH THE CC AND CV AN OUTPUT TERMINALS ARE ELECTRICALLY HOT ENERGIZED WHENEVER THE ENGINE IS RUNNING CONSTANT CURRENT CONSTANT VOLTAGE
39. closed area vent engine exhaust outside and away from any building air intakes ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables 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 1 4 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders trailer or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit 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 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 OVERHEATING can damage motors OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current o
40. consin 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 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
41. ctory Authorized Service Agent check idle module PC1 and current transformer CT1 Engine does not remain at weld power speed when power or weld load is applied with Engine Control switch in Run ldle position Place Engine Control switch in the Run position for small loads OM 486 Page 29 SECTION 8 ELECTRICAL DIAGRAM 115VAC SOURCE RC1 I RC2 4 CB6 RC1 G RC2 2 24 115VAC NEUTRAL onge RETSA RC2 6 SOURCE 115VAC RC1 J RC2 5 CONTACTOR 2avac A RC1 B RC2 7 CONTACTOR conn REE RC2 9 REF REMOTE eI Reda gt LSOPLBS 1 COMMAND E AMPLE 14 RCI D RC2 10 45 CIRCUIT 717 DIE COMMON RC1 K K CHASSIS cl FHPLOZ IY i SE PC4 CAPACITOR BOARD S2 POSITION MODE lt gt Se cries 1 aX RUN IDLE S 76 PLG9 8 5 ZAPLGI Z 2 RUN M 125 PLG8 5 z 3 START S 126 PLG9 6 7 NI el C un B D E F PLG8 38 DO 1T d b d b o 6 5 o 8 A7 als 1 D2 AA JU 33 393 GF 60 5 5H uH LOW OIL Aj T D N O 32 BY ROS N PLG5 Bun PLG5 RC5 PLG7 RC7 L Ros Y ME Le Ide Bes Er fes eg 3 IDLE BOARD esi P SS er 2 P NEE OPT LJ 0 ras T 12 VOLT dee Ze Q GOONER 5 gt er E 12 VOLT LE ED 1 V RC7 5 STARTER 16 ol Lo PLG7 A MES ET ELECTRIC IGNITION au g CO VOLT ae CONTROL REC nd Hour 4 PLG5 RECT BLACK METER RCS re 33 NEGATIVE ALTERNATOR STATOR
42. e 18 5 1 Front Panel CONTO aereo tuta d eau abe acra ora e eatis deb us cation EE SE 18 5 2 Remote Amperage Voltage Control 19 SECTION 6 OPERATING AUXILIARY EQUIPMENT 20 6 1 Auxiliary Power Receptacles And Circuit Breakers 20 6 2 Optional Auxiliary Power Receptacles 21 SECTION 7 MAINTENANCE AND TROUBLESHOOTING 22 FL outne Malntelariee o ccs vor EELER A 22 7 2 Maintenance Labels ta bep ehe ca Os oo e Pace A Ppl ho Pena o 23 Ta Servieing AIPGIeaner 35e aiia aa acit Errat cad dd ra doti basil iia 24 7 4 Servicing Optional Spark Arrestor ees 24 7 5 Changing Engine Oil Oil Filter And Fuel Filter 25 1 6 AGIUSING Engine Speed EE 26 1 72 Overload Sene eT 922v rada aa 27 7 8 HOUDISShOONO cdo ias boo Ro ntn a dem 00 s d eoe a quer Penh eO e Enea 27 SECTION S ELECTRICAL DIAGRAM Loon a aegre ee ow V ee NUR e ee v N 30 SECTION 9 AUXILIARY POWER GUIDELINES 32 SECTION 10 PAHTS EIST SEL SSSR e VE Eb nue um ES A AE O AS dt 40 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols A Marks a special safety message CS Means Note not safety related 1 2 Arc Welding Hazards A The symbols sho
43. e pelo eddie 1 TUE en ne Lr S RENE FAN OO PR RT tices RETI PPP 1 Oasis en 134 981 i ADAPTER fan TOO a naue trn ptt Eton e Eu UR Sone sun 1 Eua d ana ne eee 160 567 e ADAPTER ENGINE eise t acta dep eine EXE bee edhe Reka ened e URS 1 x Rm 197 151 OTUD Si 379 16X23 MAA hi eU SIS Weiner 4 TE qM PEDE 047 878 BAR retaining brushholder 1 r EE 161 306 CAP brushholder 3 TDi Mc 126 984 ns BRUSH W SDITIO EE 3 D KEE 0056142 HOLDER Dr slia EEN 3 ES TEE 187 183 BRACKET mtg brushholder 1 P E PETERS 1873990 EENS CONSISTING Ol TTT 1 A as 183 419 O RING 1 984 ID x 139CS 1 ICS Hardware is common and not available unless listed ST 802 050 Figure 10 3 Generator When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 486 Page 43 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
44. en quali fi les interf rences r sultant de l installation e Si le FCC signale des interf rences arr ter imm diatement l appareil e 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 distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles 1 5 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Weld ing Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement com mand 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 d
45. ervention sur la batterie e Arr ter le moteur avant 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 cable n gatif en premier lieu Le rebrancher en dernier lieu 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 LES GAZ D CHAPPEMENT DU MOTEUR peuvent provoquer des accidents mortels e Utiliser l quipement l ext rieur dans des zones ou vertes et bien ventil es e En cas d utilisation dans un endroit ferm vacuer les gaz d chappe ment du moteur vers l ext rieur distance des entr es d air dans les b ti ments 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 TINCELLES 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 1 4 Dangers sup
46. g or fire Check and be sure the area is safe before doing any welding e Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material 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 e 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 e Beaware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e 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 e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards e Do not use welder to thaw frozen pipes e Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes Wu e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool t
47. h solenoid energized slide sole noid until idle speed screw just touches carburetor stop Tighten solenoid mounting screws 7 Governor Arm Extension Check for smooth operation and readjust solenoid position if necessary Weld Power Speed Adjustment Place Engine Control switch in Run position 8 Weld Power Speed Rod 9 Locking Nut Loosen nut 10 Adjustment Nut Turn adjustment nut until engine runs at weld power speed Tighten locking nut Stop engine 11 Sensitivity Spring See engine manual for governor sensitivity adjustment Ref ST 801 942 C ST 800 397 A 7 7 Overload Protection a 1 e Stop engine y Tools Needed EX CA a 3 When a circuit breaker or fuse LT AR oh opens it usually indicates a more serious problem exists Contact a Factory Authorized J C 3 8 in Service Agent 1 Circuit Breaker CB5 CB5 protects the 24 volt ac output to Remote 14 receptacle RC1 If CB5 opens 24 volt ac output to RC1 stops 2 Circuit Breaker CB6 CB6 protects the 115 volt ac output to Remote 14 receptacle RC1 If CB6 opens 115 volt ac output to RC1 stops Press button to reset breaker 3 Fuse F6 See Parts List F6 protects the engine wiring sys tem from overload If F6 opens engine will not crank 4 Fuse F1 See Parts List 5 Fuse F2 See Parts List Remove side panel 0 RUN IDLE RUN y START F1 protects the exciter excitation w
48. hey can throw off slag e Wear approved safety glasses with side shields even under your welding helmet 4 a 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 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 e Do not overfill tank allow room for fuel to expand e Do not spill fuel If fuel is spilled clean up before starting engine e Dispose of rags in a fireproof container OM 486 Page 2 HOT PARTS can cause severe burns e Allow cooling period before maintaining e Wear protective gloves and clothing when working on a hot engine e Do not touch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully e Protect compressed
49. igilant Il y a des risques de danger reli s aux CHOCS LECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de connaitre les mesures prendre pour viter tout danger e Nutiliser 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 e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le cable de retour de fa on 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 soler 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 apres 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 compo sants LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre appropri pour pr
50. inding from overload If F1 opens weld and auxiliary power output stops F2 protects the stator winding from overload If F2 opens weld output stops Auxiliary power will still be available Replace any open fuses Reinstall cover before operating unit 714 CONTROL ST 801 945 C Ref ST 189 925 A 7 8 Troubleshooting A Welding Trouble Remedy No weld output Check control settings Check weld connections Disconnect equipment from auxiliary power receptacles during start up Place Output Contactor switch in On position or move switch to Remote 14 position and connect remote contactor to Remote 14 receptacle RC1 see Sections 4 8 and 5 1 Check fuses F1 and F2 and replace if necessary see Section 7 7 Have Factory Authorized Service Agent check brushes slip rings and field current control board PC2 OM 486 Page 27 Trouble Remedy Low weld output Check control settings Place Remote Amperage Voltage switch in Panel position or move switch to Remote 14 position and connect remote amperage voltage control to Remote 14 receptacle RC1 Check and clean air cleaner as necessary see Section 7 3 Check and adjust engine speed see Section 7 6 Have Factory Authorized Service Agent check brushes slip rings and field current control board PC2 See engine manual High weld output Check control settings
51. lean cooling system See Clean and engine manual tighten weld terminals Q 100 h Change oil See Section 7 5 and maintenance label Change oil filter See Section 7 5 and maintenance label Service air filter element See Section 7 3 Clean and tighten battery connections 200 h Check valve Replace fuel Clearance filter See Section 7 5 Replace Check spark plugs unreadable labels 500 h Repair or Service welding generator replace cracked brushes and slip rings Service more often in dirty cables m j conditions 1000 h Remove cylinder head deposits Clean crankcase breather valve Blow out or En vacuum inside During heavy OR service clean monthly OM 486 Page 22 7 2 Maintenance Label N OTE Follow the storage procedure in the engine owner s manual if the unit will not be s used for an extended period ONAN P216 P220 GAS ENGINE AN See Engine Manual for complete engine care Give Engine Specification and Serial Number when ordering parts To Drain Oil Push And 7 Check Turn CCW Daily f A 4 R I ve in ID Hose mb Pu Recommended Oil API Service Classification SF CC SG CE SH CONDITIONS Severe 100 hours 50 hours 50 hours 50 hours Oil Filter MILLER 065 251 Onan 122 0645 Oil Capacity 1 5 qt 1 4L or 1 75 qt 1 6L with filter change Fuel Grade Regular or Unleaded Fuel Filter
52. 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 7 00 Owner s Record Please complete and retain with your personal records Model Name Purchase Date Distributor Address City State Serial Style Number Date which equipment was delivered to original customer For Service Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA 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 File a claim for loss or damage during shipment 2000 Miller Electric Mfg Co 6 00 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
53. lt ac circuits GND ST 801 943 B K Chassis common The remaining sockets are not used OM 486 Page 16 4 9 Adjusting MIG Weld Puddle Consistency pa e 712 ed OFF y RUN IDLE RUN y START Tools Needed gt YX 3 8 7 16 in Stop engine Stabilizer DC Z is factory connected to suit most MIG Wire Welding applications To change MIG weld puddle consis tency proceed as follows Remove lower front panel and side panel Starting from center of DC Z the three leads 79 will be referred to as inner middle and outer Stabilizer DC Z Inner Lead 79 Middle Lead 79 Outer Lead 79 Wire CV Weld Output Terminal Middle lead 79 is connected to Wire CV weld terminal at the factory Disconnect middle lead 79 from terminal Qn A N To wet out weld puddle Remove insulation sleeve from in ner lead 79 Connect inner lead 79 to Wire CV terminal reusing hardware To stiffen weld puddle Remove insulation sleeve from out er lead 79 Connect outer lead 79 to Wire CV terminal reusing hardware Slide sleeves over unused leads 79 and secure with cable ties Reinstall panels ST 801 944 C Ref ST 189 925 A OM 486 Page 17 9 1 SECTION 5 OPERATING WELDING GENERATOR Front Panel Controls A ELECTRODE SM POSITIVE a a OFF ES ANN CONTROL 1 up RUN IDLE WARNING ELECTRIC SHOCK CAN KILL DO NOT USE AC OUTPU
54. mes Do not breathe the fumes e lf inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator e Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated 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 if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 486 Page 1 f 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 overheatin
55. mulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 DEFINITIONS 2 1 Symbol Definitions Fast Fast Slow Gi PE e Run Weld Power lt a Run ldle s Slow Idle Vi Start Engine Panel Local Temperature E Fuel Le Engine Oil On piii Battery Engine DE Engine PR S edd S Amperes V Volts f e e E j Stick SMAW A TIG GTAW 5 Circuit Breaker Positive Negative Ny ir id gt Output D Time h Hours S Seconds D ro ji Do not switch while Remote 14 CU E welding A 14 Receptacle s e Work Connection Lt Engine Choke olo Wire Feed A Cdi o YA Electrode Negative CE o ositive es 3 1 Weld Power And Engine Specifications Rated Maximum Amperage Voltage me ati Welding Open Circuit Range In Range In p Pen d C a e ae Engine Output Voltage CC Mode CV Mode H SS 250 A 25 V CC DC 10096 Duty 80 40 250A Cycle Continuous 8 kVA kW Onan P220 66 6 33 3 A Air Cooled 250 A 25 V ed E 120 240 V AC 60 Hz 10 gal 38 L Two Cylinder CV DC 100 Yo Duty 50 Sz 10 40 V Single Phase K Four Cycle nds Peak 9 kVA KW 20 HP Gasoline 200 A 25 V w Weld Contactor Off Engine CC AC 60 Duty 75 40 200A Cycle OM 486 Page 9 3
56. ns and tighten if necessary Check plug PLG5 and plug PLG8 connections Have Factory Authorized Service Agent check Engine Control switch S5 Engine does not start Check fuel level see Section 4 2 Check battery and replace if necessary Check engine charging system according to engine manual See engine manual Engine starts but stops when Engine Control switch returns to Run position Check oil level see Section 4 2 Check and refill crankcase with proper viscosity oil for operating temperature if necessary see Sec tion 7 2 Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 Battery discharges between uses Clean 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 4 2 Check oil level see Section 4 2 Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 Engine does not return to idle speed Be sure Engine Control switch S2 is in Run ldle position Remove all weld and auxiliary power loads Turn off remote device connected to Remote 14 receptacle RC1 see Section 4 8 Check for obstructed movement of solenoid linkage see Section 7 6 Have Fa
57. nts e 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 Ne jamais toucher les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne comportant pas de trous e Sisoler de la pi ce et de la terre au moyen de tapis ou d autres moyens iso lants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique acourant lectrique dans les zones humides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique acourant lectrique UNIQUEMENT si le proc d de soudage le demande e GSil utilisation d une source lectrique acourant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip e Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l ent
58. o t ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas regarder l arc e Porter des v tements de protection constitu dans une mati re durable r sistant au feu laine ou cuir et une protection des pieds LES FUM ES ET LES GAZ peuvent tre dangereux 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 l interieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur alimentation d air homologu e Lire les sp cifications de s curit des mat riaux MSDSs et les instruc tions 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 por tant 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
59. of reliable service with proper maintenance And if for some reason the unit needs repair there s a REGISTERED QUALITY SYSTEM Troubleshooting section that will help you Miller is the first welding figure out what the problem is The parts list equipment manufacturer in E Ee will then help you to decide which exact part the ISO 9001 Quality System you may need to fix the problem Warranty and alan dara service information for your particular model are also provided Miller offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local distributor Your distributor can also supply you with Welding Process Manuals such as SMAW GTAW GMAW and GMAW P Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual catalog 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 Miller The Power of Blue 4 amp WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq 4 amp WAR
60. ompany Service Meter 2 Main and Branch Overcurrent Protection 3 Double Pole Double Throw Transfer Switch Obtain and install correct switch Switch rating must be same as or greater than the branch overcurrent protection 4 Circuit Breakers or Fused Disconnect Switch Obtain and install correct circuit breakers or switch 5 Extension Cord Select as shown in Section 9 11 6 Generator Connections Connect terminals or plug of ade quate amperage capacity to cord Follow all applicable codes and safety practices 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 7 Load Connections Item 4 is not necessary if circuit protection is already present in welding generator auxiliary power output circuit S 0405 A OM 486 Page 37 9 11 Selecting Extension Cord Use Shortest Cord Possible NT Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG urreni 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
61. oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration 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 former des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvani S plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n ces saire 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 OM 486 Page 5 gt LE SOUDAGE peut provoquer un in FS cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal
62. pl mentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil lui m me sans chariot de bouteilles de gaz remorque ou autres accessoires e Utiliser un quipement de levage de capacit suffi sante pour lever l appareil e En utilisant 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 LES TINCELLES VOLANTES ris quent de provoquer des blessures e Porter un cran facial pour prot ger le visage et les yeux e Affuterr l lectrode au tungst ne uniquement la meuleuse dot e de pro tecteurs Cette manoeuvre 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 substance inflammable LE SURCHAUFFEMENT peut endom mager le moteur lectrique e 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 endommager 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 s il y a lieu Lamm UT Ge e P LV 4 Us C ei Bes
63. poolmate 185 amp Spoolmate 250 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 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 based 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 Wis
64. r reduce duty cycle before starting to weld again e Do not block or filter airflow to unit STATIC ESD can damage PC boards e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards TILTING OF TRAILER can cause injury e Use tongue jack or blocks to support weight e Properly install welding generator onto trailer according to instructions supplied with trailer READ INSTRUCTIONS e Use only genuine MILLER replacement parts e Perform engine maintenance and service according to this manual and the engine manual OM 486 Page 3 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 Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion 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 5 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550
65. rator Base Metal Vehicle Frame Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire A lfunit does not have GFCI re ceptacles use GFCI pro tected extension cord eee 74 Electrically bond generator C 2 frame to vehicle frame by metal to metalcontact OM 486 Page 32 9 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device GND PE A Ground generator to system earth ground if supplying power to a premises home shop farm wiring system Use ground device as stated in electrical codes ST 800 576 B 9 4 How Much Power Does Equipment Require 1 Resistive Load A light bulb is a resistive load and VOLTS 115 AMPS 45 Se a constant amount of pow 60 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 run ning see Section 9 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment AMPERES x VOLTS z WATTS EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin 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 Example 1 add the individual loads to calculate total load 200 W 20
66. re 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 DES ORGANES MOBILES peuvent provoquer des blessures CA e Ne pas approcher les mains des ventilateurs cour roies et autres pieces en mouvement e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection e Arr ter le moteur avant d installer ou brancher l appareil Demander seulement un personnel qualifi d enlever les dispositifs de s curit ou les recouvrements 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 entre tien d brancher le cable n gatif de batterie de la borne e Ne pas approcher les mains cheveux v tements laches et outils des or ganes mobiles e Remettre en place les panneaux ou les dipositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur e Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur e Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n rateur L EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE e Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une in t
67. retien 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 a 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 conducteur de mise la terre appropri et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un cable d nud peut provoquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante 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 ce ou le c ble de retour e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine rom nd fre 11 98 Ce groupe de symboles signifie Mise en garde Soyez v
68. rol if present on unit e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CER 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes 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 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 rom nd 11 98 This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazard
69. s 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 connected 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 after stopping engine on inverters e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts 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 a welding helmet fitted with a proper shade of filter 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 and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial wool and leather and foot protection 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 fu
70. s des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES j je peuvent blesser 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 vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou 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 respi rateur d adduction d air homologu des r servoirs tambours ou des conduites peut provoquer DES PIECES CHAUDES peuvent provoquer des br lures graves e Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien e Porter des gants et des v tements de protection pour travailler sur un moteur chaud e Ne pas toucher mains nues les parties chaudes du moteur ni les pieces r cemment soud es LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev LES CH
71. s champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir ex amin 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 Re search 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 con clusions 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 OM 486 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les cables ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos 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 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux sti
72. se interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such 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 lfinterference 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 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1HR3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 1 Keepcables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do
73. uire la possibilit d interf rence maintenir les c bles de souda ge aussi courts que possible les grouper et les poser aussi bas que pos sible ex par terre e Veiller souder une distance de 100 metres de tout quipement lec tronique 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 apres avoir pris les mesures pr c dentes il in combe 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 fil tres de ligne ou la pose de protecteurs dans la zone de travail Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Regles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 6 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme de
74. 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 drafts Increase postflow time Check and tighten all gas fittings Properly prepare tungsten OM 486 Page 28 B Auxiliary Power Trouble Remedy No power output Reset circuit breakers CB1 CB2 CB3 and or CB4 see Section 6 1 Check fuse F1 and replace if necessary see Section 7 7 Have Factory Authorized Service Agent check brushes slip rings and field current control board PC2 Low power output Check and clean air cleaner as necessary Check and adjust engine speed see Section 7 6 See engine manual High power output Check and adjust engine speed see Section 7 6 Erratic power output Have Factory Authorized Service Agent check brushes slip rings and field current control board PC2 Check receptacle wiring and connections Check governor according to engine manual C Engine Trouble Remedy Engine will not crank Check fuse F6 and replace if open see Section 7 7 Check battery voltage Check battery connectio
75. wn 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 5 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 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 equipment 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 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 f AC output is required use remote output cont

Miller Electric 251 NT Welding System User Manual

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