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Miller Electric 185 DX Welding System User Manual

1. ELECTRODE POSITION PENETRATION DEEP DEEP MIN PREP ROUGH HIGH SPATTER LOW GENERAL MED SMOOTH EASY FAST LOW LOW HYDROGEN STRONG FLAT HORIZ FILLET LOW SMOOTH EASY FASTER NI CL y Y A Y Y y ALL LOW CAST IRON 308L Y ALL LOW STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY Ref S 087 985 A 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out electrode was lifted to high If electrode sticks to work piece use a quick twist to free it S 0049 13 4 Striking an Arc Tapping Technique Il Il T e 2 2 1 Electrode 2 Workpiece 3 Arc Bring electrode straight down to workpiece then lift slightly to start arc If arc goes out electrode was lifted too high If electrode sticks to workpiece use a quick twist to free it S 0050 OM 4415 Page 44 13 5 Positioning Electrode Holder 10 30 EAT WN 907 90 a T y End View of Work Angle Side View of Electrode Angle GROOVE WELDS o o 10 30 V ga End View of Work Angle Side View of Electrode Angle
2. Cord Lengths for 120 Volt Loads A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 600 350 106 225 68 137 42 100 30 7 840 400 122 250 76 150 46 100 30 62 19 10 1200 400 122 275 84 175 53 112 34 62 19 50 15 15 1800 300 91 175 53 112 34 75 23 37 11 30 9 20 2400 225 68 137 42 87 26 50 15 30 9 25 3000 175 53 112 34 62 19 37 11 30 3600 150 46 87 26 50 15 37 11 35 4200 125 38 75 23 50 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 800 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69
3. 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 10in 5200 1600 Air Compressor 1 2 HP 3000 1000 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 Floor Polisher 3 4 HP 16 in 4500 1400 1 HP 20 in 6100 1600 High Pressure Washer 1 2 HP 3150 950 3 4 HP 4500 1400 1HP 6100 1600 55 gal Drum Mixer 1 4 HP 1900 700 Wet amp Dry Vac 1 7 HP 900 900 2 1 2 HP 1300 1300 OM 4415 Page 39 12 8 Power Required To Start Motor Single Phase Induction Motor Starting Requirements Motor Start G H J K L M N P Code KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 1 Motor Start Code 2 Running Amperage 3 Motor HP x AC MOTOR 2 4 Motor Voltage fivouts_2s0 amps 25477 ag CODE M Hz 60 To find starting amperage N HP 1 4 PHASE 1 Step 1 Find code and use t
4. Incorrect Installation 1 Positive Weld Output Terminal 2 Negative Weld Output Terminal For Direct Current Electrode Posi tive DCEP connect work cable to Negative terminal and electrode holder to Positive terminal For Direct Current Electrode nega tive DCEN reverse cable con nections A Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remove supplied nut from weld output terminal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against cop per bar Do not place anything between weld cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean Tools Needed J 8 3 4 in 803 596 B 803 778 A 5 7 Selecting Weld Cable Sizes For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 Weld Cable Size and Total Cable Copper Length in Weld Circuit T Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100ft 30m orLess 45m 60m 70m 90m 105 m 120 m 10 60 60 100 Ad Duty Duty 10
5. OM 4415 209 416F 2007 05 Miller e Stick SMAW Welding Description D a I Engine Driven Welding Generator I o O Z LU ESPANOL Blue Star 185 Blue Star 185 DX OWNER S MANUAL File Engine Drive pa 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 tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U E Bl E PEENI This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hard as you do every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count o
6. Tune up engine according to engine manual OM 4415 Page 32 I Complete Parts List available at www MillerWelds com SECTION 10 PARTS LIST 10 1 Recommended Spare Parts Dia Part Mkgs No Description Quantity Recommended Spare Parts TCU 220305 Tune up amp Filter Kit Honda includes ROI 190108 Spark PIUQ e A AA la E a d LE lin eae ao 2209303 AIT PINOT a M Le YI Seagate rae Deer ere eee eee Od avo Shed de Mar URNA ds 220304 AirFilter Pre Cleaner 1 usus fam Reap A ae 221584 Tune up amp Filter Kit Kohler CS 10 amp 12 Electric includes an 203960 2 45 Spark Pl g uri ea 1T NE MEE hf 221582 Filter Air Kohler CS 10 amp 12 Electric 1 A A A 221583 Filter Air Pre Cleaner Kohler CS 10 amp 12 Electric 1 OM 4415 Page 33 SECTION 11 ELECTRICAL DIAGRAMS amp WARNING e Do not touch live electrical parts t e Disconnect input power or stop UN N engine before servicing 7 Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or
7. 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death e Do not use compressed air for breathing e Use only for cutting gouging and tools COMPRESSED AIR can cause injury e Wear approved safety goggles e Do not direct air stream toward self or others STEAM AND HOT COOLANT can burn e f possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual e Ifthe engine is warm checking is needed and there is no over flow tank follow the next two statements e Wear safety glasses and gloves and put a rag over radiator cap e Turn cap slightly and let pressure escape slowly before completely removing cap Using a generator indoors CAN KILL YOU IN MINUTES e Generator exhaust contains carbon monoxide This is a poison you cannot see or smell e NEVER use inside a home or garage EVEN IF doors and windows are open e Only use OUTSIDE and far away from windows doors and vents BATTERY ACID can BURN SKIN and EYES e Do not tip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire
8. 1 Generator Power Receptacles Neutral Bonded To Frame 2 8 Prong Plug From Case Grounded Equipment 3 2 Prong Plug From Double Insulated Equipment EF Be sure equipment has double insulated symbol and or word ing on it Do not use 2 prong plug un less equipment is double in sulated gen pwr 2007 04 Ref ST 159 730 ST 800 577 A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Arse see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire gt Electrically bond generator frame to vehicle frame by met al to metal contact A Bed liners shipping skids and some running gear insu late the welding generator from the vehicle frame Al ways connect a ground wire from the generator equip ment grounding terminal to bare metal on the vehicle frame as shown If unit does not have GFCI re ceptacles use GFCI pro tected extension cord S 0854 OM 4415 Page 36 12 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire
9. FILLET WELDS S 0060 13 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration OO BR ND S 0053 A 13 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 NoOverlap 5 Good Penetration into Base Metal S 0052 B OM 4415 Page 45 13 8 Conditions That Affect Weld Bead Shape gt Weld bead shape is affected by electrode angle arc length travel speed and thickness of base metal Correct Angle Angle Too Small b 4 10 30 Angle Too Large a E panna EA 4 prag ELECTRODE ANGLE L poe cz gon eres Too Short Normal Too Long ARC LENGTH SSS hs Se Slow Normal Fast TRAVEL SPEED S 0061 13 9 Electrode Movement During Welding FF Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 1 2 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode Do not let weave width exceed 2
10. e Mettre des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur e D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon L utilisation d un groupe autonome l int rieur PEUT VOUS TUER EN QUELQUES MINUTES e Les fum es d un groupe autonome contient du monoxyde de carbone C est un poison invisi ble et inodore e JAMAIS utiliser dans une maison ou garage m me avec les portes et fen tres ouvertes e Uniquementutiliser PEXTERIEUR loin des portes fen tres et bouches a ration L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU e Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau 2 4 Dangers li s l air comprim RESPIRER L AIR COMPRIM peut pro voquer des blessures graves ou causer la mort e Ne pas utiliser l air comprim pour respirer e Utiliser l air comprim seulement pour le cou page gougeage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit approuv es e Ne pas diriger le jet d air vers d autres ou Soi m me L AIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo quer des blessures e Rel cher la pression d air de l outillage ou du syst me avant d effectuer la maintenance avant de changer ou de rajouter des l ments ou av
11. min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation LAW 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z8
12. 100 Duty Cycle P Cycle Cycle Weld Output Terminals 100 4 20 4 20 4 20 3 30 2 85 1 50 1 0 60 1 0 60 Stop engine before conneding to weld 150 3 30 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 3 0 95 output terminals 200 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 A Do not use worn dam aged undersized or 2 ea 2 0 2 ea 2 0 poorly spliced cables 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 70 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 STU ee o This chart is a general guideline and may not suit all applications If cables overheat use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use S 0007 F OM 4415 Page 20 I Complete Parts List available at www MillerWelds com Notes DECIMAL EQUIVALENTS 015625 T Oe So 9 8 ve 066 5 oo MP ve e 9 dez 06 6 eo e oe 609 e e 9 ve 9 0 60 Nt 6 ve o 6 Bk ve e o9 ve 0 0 66 o OM 4415 Page 21 SECTION 6 OPERATING THE WELDING GENERATOR 6 1 Controls Standard Models See Section 6 2 OM 4
13. e Do not let engine exhaust sparks cause fire e Use approved engine exhaust spark arrestor in required areas see applicable codes TRAPPED AIR PRESSURE AND WHIPPING RY HOSES can cause injury e Release air pressure from tools and system be fore servicing adding or changing attach ments or opening compressor oil drain or oil fill cap OM 4415 Page 3 HOT METAL from air arc cutting and gouging can cause fire or explosion Lh e Do not cut or gouge near flammables e Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury e Do not touch hot compressor or air system parts e Let system cool down before touching or ser vicing READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit Stop engine and release air pressure before servicing Use only genuine replacement parts from the manufacturer 1 5 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit and properly installed accessories only NOT gas cylinders Do not exceed maximum lift eye weight rating see Specifications e Lift and support unit only with p
14. e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial y LES FUM ES ET LES GAZ peuvent tre dangereux R Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e A l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op
15. il est recommand de suivre les proc dures pr c dentes OM 4415 Page 11 I Complete Parts List available at www MillerWelds com SECTION 3 DEFINITIONS 3 1 Symbol Definitions o Engine Choke 3 dee i A Amperes V Volts SEES Engine Oil E Fuel Battery Engine O lt Engine Positive Negative NU Alternating Current Output AC h Hours S Seconds e Time D ro d e xe Circuit Protector Temperature 4 1 Weld Power And Engine Specifications E Weld Maximum Welding Rated PRA Generator Fuel A Mode Eto Welding Output ers ur Power Rating Capacity Engine Standard Model Honda GX390 Air Cooled One Cylinder Four Cycle 185 25 V Single Phase Standard Model 13 HP 390 CC 20 Duty Cycle 6 kVA kW Peak 1 7 gal 6 9 L Gasoline Engine CC DC 55 185A 130 redd 80 Co in ank Ree E ontinuous 60 Duty Cycle 40 23 A DX Model DX Model 100 25 V 120 240 V AC 5 gal 19 L Kohler CS12 75 100 Duty Cycle 60 Hz Tank Air Cooled One Cylinder Four Cycle 12 75 HP 360 CC Gasoline Engine Electric Start OM 4415 Page 12 I Complete Parts List available at www MillerWelds com 4 2 Dimensions Weights And Operating Angles Dimensions Height 22 3 4 in 578 mm Width 22 3 4 in 577 mm D L j Y o o A Do not move or operate unit where it could tip Do not exceed tilt angles or en gine coul
16. rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures oi m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respirateur d adduction d air homologu LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux e sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des lunettes de s curit avec crans lat raux m me sous votre c
17. 1 2 times diameter of electrode 3 Z UC YM S 0054 A OM 4415 Page 46 13 10 Butt Joints 1 30 1 16 in 1 6 mm 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be fore final weld 2 Square Groove Weld Good for materials up to 3 16 in 5 mm thick 3 Single V Groove Weld Good for materials 3 16 3 4 in 5 19 mm thick Cut bevel with oxy acetylene or plasma cutting equip ment Remove scale from material after cutting A grinder can also be used to prepare bevels Create 30 degree angle of bevel on materials in V groove welding 4 Double V Groove Weld Good for materials thicker than 3 16 in 5 mm S 0662 13 11 Lap Joint 30 o 30 Or Less Or Less A 1 RA 2 3 Single Layer Fillet Weld Multi Layer Fillet Weld 1 Electrode 2 Single Layer Fillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fore making another weld pass Weld both sides of joint for maxi mum strength S 0063 S 0064 13 12 Tee Joint 1 Electrode 2 Fillet Weld Keep arc short and move at definite rate of speed Hold electrode as shown to provide fusion into the corner Square edge of the weld surface For maximum strength weld b
18. 125 38 75 23 45 10 800 200 61 125 38 50 12 000 175 53 100 31 Conductor size is based on maximum 2 voltage drop OM 4415 Page 42 SECTION 13 STICK WELDING SMAW GUIDELINES ES A LAS Ww A gf 13 1 Stick Welding Procedure Tools Needed LL mmm Aweia current starts when elec Aweia current can damage elec trode touches workpiece tronic parts in vehicles Discon nect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible 1 Workpiece Make sure workpiece is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode requires less current than a large one Fol low electrode manufacturer s instructions when setting weld am perage see Section 13 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp crackling sound 7 Slag Use a chipping hammer and wire brush to remove slag Remove slag and check weld bead before mak ing another weld pass Stick 2007 04 ST 151 593 OM 4415 Page 43 13 2 Electrode and Amperage Selection Chart AMPERAGE RANGE ELECTRODE DIAMETER 250 300
19. 3 Ground Device EF Use ground device as stated in electrical codes A Ground generator to system earth ground if supplying power to a premises home shop farm wiring system so see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators ST 800 576 B 12 4 How Much Power Does Equipment Require 60 VOLTS 115 AMPS 4 5 Hz 60 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 12 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run ning power requirement in watts 4 5Ax115V 2 520W The load applied by the drill is 520 watts Example 2 If three 200 watt flood lamps are used with the drill from Ex ample 1 add the individual loads to calculate total load 3 x 200W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts S 0623 OM 4415 Page 37 12 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 1
20. G C 2 2500 100 rpm 42 Hz 3750 30 rpm 62Hz After tuning engine check engine speed See table for proper no load speed If necessary adjust speed as follows Start engine and run until warm Set Weld Output Control to Max Weld Power Speed Adjustment 1 Adjustment Screw To increase speed turn screw out counterclockwise To decrease speed turn screw in clockwise Idle Speed Adjustment 2 Throttle Solenoid TS1 3 Adjustment Screw Loosen two screws on side of throttle solenoid TS1 Adjust TS1 until idle speed is approximately 2500 rpm Use adjustment screw to fine tune idle speed Be sure TS1 plunger bottoms at idle Tighten two screws on TS1 A Stop engine Close fuel valve 803 595 B OM 4415 Page 30 I Complete Parts List available at www MillerWelds com SECTION 9 TROUBLESHOOTING 9 1 Troubleshooting A Welding Trouble Remedy No weld output or generator power out put at ac receptacles Be sure all equipment is disconnected from receptacles when starting unit Have Factory Authorized Service Agent check brushes slip rings rotor stator integrated rectifier SR2 and Weld Output control R1 No weld output generator power out put okay at ac receptacles Check Weld Output control setting Check weld connections Have Factory Authoriz
21. Kohler Engine 80 70 60 50 40 VOLTS MIN 30 MID 20 100 150 200 250 300 AMPERES o O1 o 220 603 A 220 605 A OM 4415 Page 14 I Complete Parts List available at www MillerWelds com 4 5 Fuel Consumption Curves A Weld Output Standard B Weld Output DX Model Model Honda Engine Kohler Engine 1 00 1 00 0 80 0 80 E q 0 60 S 0 60 O O qj 0 40 ui 0 40 D D 0 20 0 20 0 00 0 00 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 DC Weld Amperes At Rated Duty Cycle DC Weld Amperes At Rated Duty Cycle 1 20 ey C Auxiliary Power Standard Model Honda Engine 1 00 I 0 80 O oi 0 60 2 0 40 0 20 2 00 0 1 2 3 4 5 6 7 8 Aux Power kW At 100 Duty Cycle 1 00 D Auxiliary Power DX Model Kohler Engine 0 80 3 0 60 O de D 0 40 0 20 0 00 0 1 2 3 4 5 6 7 8 Aux Power kW At 100 Duty Cycle 220 638 A 220 639 A OM 4415 Page 15 I Complete Parts List available at www MillerWelds com 4 6 Generator Power Curves The ac generator power curves show the generator power available A Power Output Standard in amperes at the receptacles Model Honda Engine 300 250 200 o 240 VOLT E O 150 gt 100 120 VOLT 50 0 0 10 20 30 40 50 60 70 80 AMPERES B Power Output DX Model Kohler Engine 300 250 200 240 VOLT D o 150 gt 100 50 10 20 30 40 50 60 70 80 AMPERES 2
22. LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N utiliser que les pi ces de rechange recom mand es par le constructeur e Effectuer la maintenance et le service du moteur et du compres seur d air suivant les instructions dans ce manuel ou le manuel du moteur compresseur si applicable y El UNE REMORQUE QUI BASCULE peut LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation e L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une dis tance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf re
23. Light Light goes on and engine stops if engine oil level is too low Engine cannot be restarted until sufficient oil is added stop engine and add oil if light goes on see Section 5 4 3 Starter Handle Use starter handle to start unit if electric start does not work 4 Choke Control Use control to change engine air fuel mix Move control to far right if starting a cold en gine Move control to far left if starting a warm engine The engine starts at weld power speed and runs at weld power speed under weld or gen erator power load The engine returns to idle speed 12 seconds after start up or after weld or generator power load is removed To Start e Open fuel valve see Section 5 4 e Setchoke e Electric Start Turn Engine switch to Start position Recoil Turn Engine switch to On posi tion Pull starter handle until engine starts e Open choke as engine warms A If the engine does not start let engine come to a complete stop before attempting restart To Stop e Turn Engine switch to Off I Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flooding and make starting difficult 5 Welding Range Table Use table to determine correct weld amper age based on electrode size type and mate rial thickness 6 Run Idle Switch Use switch to select whether the engine stays at run speed continuously or whether the auto idle feature is enabled
24. Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le c ble n gatif de batterie de la borne e Ne pas approcher les mains cheveux v tements laches et outils des organes mobiles Remettre en place les panneaux ou les dispositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur e Bloquerle volant moteur pour viter sa rotation lors d une interven tion sur le g n rateur DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chau des e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e l est pr f rable de v rifier le liquide de refroi dissement une fois le moteur refroidi pour viter de se br ler e Toujours v rifier le niveau de liquide de refroidissement dans le vase d expansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer com me suivant
25. Valve Open valve I Close fuel valve before moving unit or carburetor may flood and make starting difficult Fuel Add fresh fuel before starting engine the first time see engine manual for specifications 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 Cil After fueling check oil with unit on level surface If oil is not up to full mark on dipstick add oil see en gine manual Unit stops if oil level is too low Unit cannot be restarted until sufficient oil is added I 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 803 595 B Tools Needed Ie 41 in Turn Engine Switch to Off DX models only A Connect negative cable last 803 596 B 803 466 OM 4415 Page 19 IT Complete Parts List available at www MillerWelds com 5 6 Connecting To Weld Output Terminals es e DNA Correct Installation OS Se v eZ SON NES SN O Do not place anything between weld cable terminal and copper bar
26. circuit Engine will not start Check fuel level see Section 5 3 or 5 4 Move choke control to correct position see Section 5 3 or 5 4 Open fuel valve see Section 5 3 or 5 4 Close fuel valve before moving unit or carburetor may flood and make starting difficult Check battery voltage DX models only Check battery connections and tighten if necessary DX models only Check oil level see Section 5 3 or 5 4 Engine stops if oil level is too low Refill crankcase with proper viscosity oil for operating temperature Have Factory Authorized Service Agent check low oil level shutdown switch Engine stopped during normal operation Check fuel level see Section 5 3 or 5 4 Open fuel valve see Section 5 3 or 5 4 Close fuel valve before moving unit or carburetor may flood and make starting difficult Check oil level See Section 5 3 or 5 4 Engine stops if oil level is too low Battery discharges between uses DX models only Clean battery terminals and posts with baking soda and water solution rinse with clear water Periodically recharge battery approximately every 3 months Replace battery Check engine battery charging circuit and connections according to engine manual Unstable or sluggish engine speeds Check engine speed and adjust if necessary see Section 8 3 or 8 4 Check throttle governor linkage for smooth non binding operation
27. completely with base metal or a preceeding weld bead y AN Possible Causes Corrective Actions Insufficient heat input Increase amperage Select larger electrode and increase amperage Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 13 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove Improper weld technique Keep arc on leading edge of weld puddle Insufficient heat input Increase amperage Select larger electrode and increase amperage Reduce travel speed 13 18 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneath weld Excessive Penetration Good Penetration Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or m
28. cotton or wool and foot protection AA WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side OM 4415 Page 2 Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire ha
29. endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage Tm i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT e Laisser l quipement refroidir respecter le fac teur de marche nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 4415 Page 10 entrainer des blessures e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remor que comme indiqu dans le manuel s y rappor tant LIRE
30. equipment manufacturer s Transportation Department PRINTED IN USA 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com C Miller
31. qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation 2 7 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 8 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les cables 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 exa
32. service this unit 106 PENEN EA BLUE STAR 185 120V 105 ET MODEL Y WG 91 So 12 E M aes 82 82 ain gore 42 2 105 106 57 BS je 90 G4 POWER 106 AUX EX RC3 117 REVOLVING FIELD 47 90 120V Y WG e WELD 122 42 OQ A1 A AC Z CB 25 RC2 BLUE STAR 185 MODEL _ lan 97 SPARK IGNITION O oc 42 PLUG UNIT rh cB1 9 ii Sp Am OIL RC1 I imon stop sow Z yx 6 SWITCH 240V RECOIL START KOHLER HONDA ENGINE DC Z 16 E ELECT A B C D E te ITO oO o o L d A EI 82 83 64 T b BASE PANEL 51 42 90 84 WORK GROUND GROUND 15 O l BLUE STAR 185 MODEL GFCI 3 97 DBS Le vYvvYvY nee E Hc MEETING p 20 42 GND N h A AA IIA d GFCI 2 ATOS 1 95 de Y Y Y T I z H CB2 IL p o BLUE STAR id 4 GND 185 p LMODEL a ph L A A A GFCI RECEPTACLE OPTION 226 737 A OM 4415 Page 34 Figure 11 1 Circuit Diagram For Standard Models 106 105 X ry 110 N SR Y 2 XF R1 105 a AUX EX Un c1 gt 122 42 45 G E PC IDLE BOARD HOUR e 8H 46 METER 46 ie c a 217 tw CRA 7 IDLE ON OFF 47 o 1 td 4 A T E LOW OIL 49 2 VOLT p E LEVEL STARTER O 1s1 amp 0 gt 9 TN p ALTE
33. weld as possible About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended OM 4415 Page 5 SECTION 2 CONSIGNES DE SECURITE LIRE AVANT UTILISATION rom 2007 04fre A Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud Signification des symboles 2 1 DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r s
34. years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as micro processors computers and computer driven equipmentsuch as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive h
35. 0 AWG or larger insulated copper wire 3 Ground Device 7 Use ground device as stated in electrical codes 800 576 B Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil 1 Fuel Valve Open valve 77 Fuel valve is shown in the open position Always close fuel valve after stopping unit Mov ing unit with fuel valve open may cause carburetor flooding and make starting difficult Fuel Add fresh fuel before starting engine the first time see engine manual for specifications 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 Cil After fueling check oil with unit on level surface If oil is not up to full mark on dipstick add oil see en gine manual Unit stops if oil level is too low Unit cannot be restarted until sufficient oil is added Ref 803 597 B Ref 802 099 OM 4415 Page 18 5 4 Engine Prestart Checks DX Model IT Complete Parts List available at www MillerWelds com Y Gasoline I Fuel valve is shown in the open position Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flooding and make starting difficult Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil 1 Fuel
36. 20 589 A 220 594 A OM 4415 Page 16 I Complete Parts List available at www MillerWelds com SECTION 5 INSTALLATION 5 1 Installing Welding Generator Movement Airflow Clearance Location aways securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes OR Do not install unit where air flow is restricted or engine may overheat A Always ground generator frame to vehicle frame to prevent elec tric shock and static electricity hazards 1 Metal Vehicle Frame 2 Equipment Grounding Terminal 3 Grounding Cable A Bed liners shipping skids and some running gear insulate the welding generator from the ve hicle frame Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown Use 10 AWG or larger insulated copper wire to make metal to met al grounding connection At unit does not have GFCI receptacles use GFCI protected extension cord Ref 151 556 Ref 800 652 803 597 B S 0854 OM 4415 Page 17 5 2 Grounding Generator When Supplying Building Systems I Complete Parts List available at www MillerWelds com Ground generator to system earth ground if supplying power to a premises home shop farm wiring system 1 Equipment Grounding Terminal 2 Grounding Cable Use 1
37. 415 Page 22 I Complete Parts List available at www MillerWelds com 6 2 Description Of Controls Standard Models See Section 6 1 1 Engine Switch Use switch to control ignition circuit Turn Switch to On position when starting engine Turn switch to Off position to stop engine En gine cannot be started with switch in the Off position Engine stops if oil level is too low Engine can not be restarted until sufficient oil is added 2 Starter Handle 3 Choke Control Use control to change engine air fuel mix Move control to far right if starting a cold en gine Move control to far left if starting a warm engine To Start e Open fuel valve see Section 5 3 e Turn Engine switch to On e Set choke e Pull starter handle Open choke as en gine warms A If the engine does not start let engine come to a complete stop before attempting restart To Stop e Turn Engine switch to Off I Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flooding and make starting difficult 4 Welding Range Table Use table to determine correct weld amper age based on electrode size type and mate rial thickness 5 Weld Output Control F Set control at maximum for full generator power output at AC receptacles Use control to select weld amperage Control may be adjusted while welding To Set Weld Output Control Use table to determine correct size electrode
38. 600 600 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 12 6 Approximate Power Requ irements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1HP 6100 1600 1 1 2 HP 8200 2200 2HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 8 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 4415 Page 38 12 7 Approximate Power Requirements For Contractor Equipment
39. 7 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standardfor Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure Des implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve
40. ON 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 2 1 Signification des symboles 2 2 Dangers relatifs au soudage l arc 2 3 Dangers existant en relation avec le moteur 2 4 Dangers li s l ai comprim 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 2 6 Proposition californienne 65 Avertissements 2 7 Principales normes de s curit 2 8 Information EMF SECTION 3 DEFINITIONS SECTION 4 SPECIFICATIONS 4 1 Weld Power And Engine Specifications 4 2 Dimensions Weights And Operating Angles 4 3 Duty Cycle 4 4 Volt Ampere Curves 4 5 Fuel Consumption Curves 4 6 Generator Power Curves SECTION 5 INSTALLATION 5 1 Installing Welding Generator 5 2 Grounding Generator When Supplying Building Systems 5 3 Engine Prestart Checks Standard Model 5 4 Engine Prestart Checks DX Model 5 5 Connecting The Battery DX Models Only 5 6 Connecting To Weld Output Terminals 5 7 Selecting Weld Cable Sizes SECTION 6 OPERATING THE WELDING GENERATOR s
41. RNATOR STATOR VOLT IGNITION RECT 40 UNIT TI rh TI TI Tl TI ELECTRIC START KOHLER ENGINE BLUE STAR 185 MODEL GFCI 3 CB3 ep 97 2 H LOC 3j z cH IO m 90 S 42 GND N GFCI 2 r 7 y7 94 e H 95 Eee t ug H cg IL 22 yn e BLUE STAR 45 wp N 185 LMODEL a h L A A GFCI RECEPTACLE OPTION 45 BLUE STAR 185 120V 8S MODEL Y W G YYY g2 106 81 8S POWER 64 REVOLVING FIELD 87 WELD 42 oe S4 AN LA ma CB2 95 cn LU A A A rez BLUE STAR 1185 MODEL _ 87 M 21 al 6 D 94 F TOO RC1 74 x G 240V DC Z VR1 A 9 16 ELECT SR1 MN m ZN 4 e WORK 15 5 42 A B C DNE F 1T O o o BASE PANEL 81 82 83 84 42 GROUND GROUND 87 42 90 84 42 81 82 42 42 4 WARNING e Do not touch live electrical parts Disconnect input power or stop x engine before servicing Do not operate with covers removed ELECTRIC e Have only qualified persons install SHOCK HAZARD use or service this unit 226 738 A Figure 11 2 Circuit Diagram for DX Models OM 4415 Page 35 SECTION 12 GENERATOR POWER GUIDELINES x The views in this section are intended to be representative of all engine driven welding generators Your unit may differ from those shown 12 1 Selecting Equipment
42. able 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 motors running amperage KVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 KVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes S 0624 12 9 How Much Power Can Generator Supply 1 Limit Load To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5Second Rule If motor does not start within 5 seconds turn off power to prevent motor damage Motor requires more power than generator can supply Ref ST 800 396 A S 0625 OM 4415 Page 40 12 10 Typical Connections To Supply Standby Power SN Utility Electrical Service Transfer Switch Essential Loads Fused Disconnect Switch If Required o Welding Generator Output A Have only qualified persons perform these connections according to all applicable codes and safety practices A Properly install and ground this equipment acco
43. age slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protective clothing when working on a battery e Stop engine before disconnecting or connect ing battery cables or servicing battery Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Disconnect negative cable first and connec
44. aintain steady travel speed OM 4415 Page 49 13 19 Troubleshooting Burn Through Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed 13 20 Troubleshooting Waviness Of Bead Lat gt lt Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 13 21 Troubleshooting Distortion Distortion contraction of weld met al during welding that forces base metal to move a Base metal moves in the direction of the weld bead Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower amperage for electrode Increase travel speed Weld in small segments and allow cooling between welds OM 4415 Page 50 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 answer
45. and wa ter solution Allow precleaner to air dry completely Dip precleaner in clean engine oil Squeeze out excess oil The engine will smoke if precleaner contains too much oil Replace paper element if dirty oily or damaged aircleaner6 9 00 803 404 OM 4415 Page 28 I Complete Parts List available at www Miller Welds com 8 3 Adjusting Engine Speed Honda Powered Units After tuning engine check engine eT Cy speeds See table for proper no load speeds If necessary adjust speeds as follows lt gt 1400 150 rpm Start engine and run until warm Weld Power Speed 3750 30 rpm 62 Hz Adjustment 1 Throttle Control Lever 2 Adjustment Screw Move lever to Run far left position Turn screw and move lever until en gine runs at weld power speed Idle Speed Adjustment 3 Pilot Screw 4 Throttle Stop Screw Move lever to idle far right posi tion Turn pilot screw until engine runs at highest idle speed Turn stop screw until engine runs at rated idle speed normally about 2 1 4 turns out A Stop engine Close fuel valve Tools Needed gt SS 3 S8 1 4 3 8 in 803 597 B Ref 802 101 A OM 4415 Page 29 IF Complete Parts List available at www MillerWelds com 8 4 Adjusting Engine Speed Kohler Powered Units C co Tools Needed tt Qe
46. ant d ouvrir la purge ou le bouchon de remplissage d huile LA CHALEUR DU MOTEUR peut pro voquer un incendie e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES ETINCELLES L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion Ne pas couper ou gouger proximit de pro duits inflammables e Surveillez et garder un extincteur proximit DES PIECES CHAUDES peuvent provo quer des br lures et blessures e Ne pas toucher le compresseur ou d autres l ments du circuit air comprim chauds Laisser l ensemble se refroidir avant de toucher ou d effectuer la maintenance LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil Arr ter le moteur et rel cher la pression avant d effectuer la maintenance e N utiliser que les pi ces de rechange recommand es par le constructeur 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces infla
47. arm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the
48. asque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection LE SOUDAGE peut provoquer un in FES cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchaut fement ou un incendie Avant de commencer le soudage v rifier e s assurer que l endroit ne pr sente pas de danger D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec des protections homologu s Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en tr
49. aversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proximit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple Brancher le cable de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites ge l es En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes Une fois le travail achev assurez vous qu il ne reste aucune tra ce d tincelles incandescentes ni de fla
50. ceptacles weld output okay Reset and check supplementary protectors see Section 7 1 Check receptacle wiring and connections Have Factory Authorized Service Agent check stator windings and connections at terminal block 1T High output at generator power ac receptacles Check engine speed and adjust if necessary see Section 8 3 or 8 4 OM 4415 Page 31 I Complete Parts List available at www MillerWelds com Trouble Remedy Low output at generator power ac receptacles Check Weld Output control setting Check engine speed and adjust if necessary see Section 8 3 or 8 4 Open circuit voltage is reduced as engine speed drops Erratic output at generator power ac receptacles Check fuel level Have Factory Authorized Service Agent check connections at terminal block 1T Check receptacle supplementary protector s wiring and connections Check throttle linkage for smooth non binding operation Service air cleaner according to engine manual Check engine speed and adjust if necessary see Section 8 3 or 8 4 C Engine Trouble Remedy Engine will not crank DX models only Reset ignition circuit breaker see engine manual Check and replace ignition fuse see engine manual Check battery voltage Check battery connections and tighten if necessary Have Factory Authorized Service Agent check engine ignition
51. d be damaged or unit 13 25 64 in 340 mm could tip Depth 31 5 8 in 803 mm A 31 5 8 in 803 mm 10 9 16 in 268 mm y 22 3 4 in 577 mm A 1 9 16 in 40 mm N a 19 5 8 in 498 mm On MIO O O gt oo oo o 13 32 in 10 mm Dia Weight AN DX Model 315 lb 143 kg E 5 D Standard Model 267 Ib 121 kg ies F Optional Lifting Eye Weight Rating Engine End 803 403 803 597 B 430 lb 195 kg 4 3 Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty Continuous Welding 100 Duty Cycle at 100 Amperes CC DC 2 Minutes Welding 8 Minutes Resting 20 Duty Cycle at 185 Amperes CC DC 0 10 20 30 40 50 60 70 80 90 100 DUTY CYCLE 220 626 A OM 4415 Page 13 I Complete Parts List available at www MillerWelds com 4 4 Volt Ampere Curves The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown A Standard Model Honda Engine 80 70 60 50 40 VOLTS 30 20 0 50 100 150 200 250 300 AMPERES B DX Model
52. de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chau des e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement S il est endommag un c ble d nud peut provoquer une lectro cution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour Ne pas toucher l lectrode quand on est en contact avec la p
53. e servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil tilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et chafaudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste OM 4415 Page 6 F Indique des instructions sp cifiques APA Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3 un poste souder manuel AC avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas tra vailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien
54. e tongue jack or blocks to support weight Properly install welding generator onto trailer y E TILTING OF TRAILER can cause injury e according to instructions supplied with trailer READ INSTRUCTIONS Read Owner s Manual before using or servic ing unit Use only genuine replacement parts from the manufacturer Perform engine and air compressor mainte nance and service according to this manual and the engine air compressor if applicable manuals H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference 1 6 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts termi
55. ed Service Agent check Weld Output control R1 stator integrated rectifier SR2 stabilizer DC Z main rectifier SR1 and reactor AC Z Low weld output Check Weld Output control setting Check engine speed and adjust if necessary see Section 8 3 or 8 4 Service engine air cleaner Check weld cable size and length Have Factory Authorized Service Agent check Weld Output control R1 stator integrated rectifier SR2 stabilizer DC Z main rectifier SR1 and reactor AC Z High weld output Check Weld Output control setting Check engine speed and adjust if necessary see Section 8 3 or 8 4 Erratic weld output Check Weld Output control setting Tighten and clean connections to electrode and workpiece Use dry properly stored electrodes for Stick welding Remove excessive coils from weld cables Clean and tighten connections both inside and outside welding generator Check engine speed and adjust if necessary see Section 8 3 or 8 4 Check throttle governor linkage for smooth non binding operation B Generator Power Trouble Remedy No output at generator power ac re ceptacles no weld output Be sure all equipment is disconnected from receptacles when starting unit Have Factory Authorized Service Agent check brushes slip rings rotor stator integrated rectifier SR2 and Weld Output control R1 No output at generator power ac re
56. elding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded 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 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy
57. er in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION 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 dama
58. extended period Routine Maintenance Ei AE g Gh Y KY a Recycle engine A Stop engine before maintaining I See Engine Manual and Maintenance Label for important start up service and storage fluids information Service engine more often if used in severe conditions 17 Check Change Q Clean Replace Reference To be done by Factory Authorized Service Agent Every Section 5 3 PS gt 5 4 Hours Y Fuel Level Y Oil Level Q Oil Fuel Spills Every D Section 8 2 25 uS Hours Q Air Cleaner Precleaner Every 50 A Hours M 2 Q Weld Terminals Every A Engine 100 X E Manual Hours 12 Section 8 2 x Air Cleaner Element Q Cooling System i Spark Plug Gap Q Battery Terminals DX C Spark Arrestor Screen Models Optional on DX Models Every a WARNI 200 N o Hours E Every Engine 300 Manual Hours Valve Clearance Every Engine 500 Manual Hours PR X Weld Cables C Slip Rings x Brushes OM 4415 Page 27 8 2 Servicing Air Cleaner I Complete Parts List available at www MillerWelds com Standard Model Shown A Stop engine NOTICE Do not run engine with out air cleaner or with dirty element 1 Precleaner 2 Paper Element 77 Do not wash paper element or clean with compressed air Remove cover Wash precleaner with soap
59. for weld am perage Select electrode type and set control to corresponding amperage range on name plate Adjust control to obtain desired weld performance EXAMPLE Electrode Diameter 1 8 Electrode Type E 6013 Current Control Setting 90 120 A Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4415 Page 23 I Complete Parts List available at www Miller Welds com 6 3 Controls DX Models See Section 6 4 j o CES A Si X J D SESE ESS ANN 1200 1200 ST NE one POSITIVE MADE IN 8 B n Smee es APPLETON WI RAR SS 803 596 B 803 595 B 218 611 B OM 4415 Page 24 I Complete Parts List available at www MillerWelds com 6 4 Description Of Controls DX Models See Section 6 3 5 Me 2 4 WW hoe 1 Engine Switch Use switch to control ignition circuit Turn switch to Start position for electric start Turn switch to On position to start engine using starter handle recoil Turn switch to Off posi tion to stop engine 2 Low Oil Level
60. ges so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or
61. i ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit quand on travaille en hauteur Maintenir solidement en place tous les panneaux et capots Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apr s avoir coup l alimentation e Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des composants DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chau des e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures DES PIECES DE METAL ou DES SA EE LETES peuvent provoquer des bles sures dans les yeux
62. if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process e If AC output is required use remote output control if present on unit e Additionalsafety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes EF Indicates special instructions APA This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards e Always verify the su
63. les avec les outils en travaillant sur la batterie e Ne pas utiliser le poste de soudage pour charger les batteries ou des v hicules de d marrage rapide e Observer la polarit correcte et sur les batteries e D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion e Arr ter le moteur avant de v rifier le niveau de carburant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une source d tincelles ou d une flamme nue e Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer toul carburant renvers avant de faire d marrer le moteur Jeter les chiffons dans un r cipient ignifuge Toujours garder le pistolet en contact avec le r servoir lors du remplissage DES ORGANES MOBILES peuvent pro voquer des blessures Y e Ne pas approcher les mains des ventilateurs courroies et autres pi ces en mouvement e Maintenirferm s et fixement en place les portes panneaux re couvrements et dispositifs de protection e Arr ter le moteur avant d installer ou brancher l appareil OM 4415 Page 8 e Seules des personnes qualifi es sont autoris es enlever les por tes panneaux recouvrements ou dispositifs de protection pour effectuer s il y a lieu des travaux d entretien et de d pannage e
64. mmables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l ali mentation est correctement dimensionn e et prot g e avant de mettre l appareil en service MIC LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage pour lever l appareil et les accessoires correctement install es seuls PAS les bouteilles de gaz Ne pas d passer le poids nominal maximal de l ceilleton voir les sp cifications e Ne lever et ne soutenir l appareil qu avec de l quipement appropri et en suivant les proc dures ad quates e Enutilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil OM 4415 Page 9 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 en dommager le moteur lectrique cause d une tension et d une fr quence trop faibles e Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz n LES TINCELLES VOLANTES ris quent de provoquer des blessures N e Porter un cran facial pour prot ger le visage et les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un
65. mmes Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter OM 4415 Page 7 e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 518 pour les travaux a chaud et avoir de la surveillance et un extincteur proximit LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affec l ouie e Porter des protections approuv s pour les ore les si le niveau sonore est trop lev LES CHAMPS MAGNETIQUES peuvent affec ter des implants m dicaux Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du ga sous haute pression Si une bouteille est endomme g e elle peut exploser Du fait que les bouteilles de gaz for normalement partie du proc d de soudage les manipuler ave pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles po
66. n years NII 00012000 of reliable service with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in the U S A ta be registered to exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage 1 2 Arc Welding Hazards 1 3 Engine Hazards etm 1 4 Compressed Air Hazards 1 5 Additional Symbols For Installation Operation And Maintenance 1 6 California Proposition 65 Warnings 1 7 Principal Safety Standards 1 8 EMF Information SECTI
67. nals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 7 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 749 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 8 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17
68. nces pour l quipement lec tronique sensible tel que les ordinateurs et l quipementcommand par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 6 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants A Les batteries les bornes et autres accessoires contiennent du plomb et des compos s a base de plomb produits chimi ques dont l tat de Californie reconnait
69. oth sides of upright section 3 Multi Layer Deposits Weld a second layer when a heavi er fillet is needed Use any of the weaving patterns shown in Section 13 9 Remove slag before making another weld pass S 0060 S 0058 A S 0061 OM 4415 Page 47 13 13 Weld Test 1 Vise 3 2 Weld Joint 3 Hammer A Strike weld joint in direction shown man lle mm Bd NE 1 4 in oe 2 6 4 mm 1 RU a UNS 2 To3 in 51 76 mm E w A good weld bends over but does not break S 0057 B 13 14 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal Possible Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 13 15 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Corrective Actions Amperage too high for electrode Decrease amperage or select larger electrode Arc length too long or voltage too high Reduce arc length or voltage OM 4415 Page 48 13 16 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse
70. own in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 7 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away FA e ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equip ment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas
71. pply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one elec
72. r the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Bat
73. rding to its Owner s Manual and na tional state and local codes Customer supplied equipment is required if generator will sup ply standby power during emergencies or power out ages 1 Utility Electrical Service 2 Transfer Switch Double Throw Switch transfers the electrical load from electric utility service to the generator Transfer load back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring Connect generator with temporary or permanent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low volt age and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the prem ises If generator does not produce enough output to meet all require ments connect only essential loads pumps freezers heaters etc See Section 12 4 OM 4415 Page 41 12 11 Selecting Extension Cord Use Shortest Cord Possible P
74. roper equipment and correct procedures e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable L3 FLYING SPARKS can cause injury e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away N MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls 3 OM 4415 Page 4 WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body pn K other people or any metal when threading welding wire OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit P9 STATIC ESD can damage PC boards e Puton grounded wrist strap BEFORE handling So e boards or parts Use proper static proof bags and boxes to store move or ship PC boards Us
75. s to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way C Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY S EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or 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 delivery date of the equipmentto the original end user purchaser and not to exceed one year afte
76. se II nn 6 1 Controls Standard Models See Section 6 2 6 2 Description Of Controls Standard Models See Section 6 1 6 3 Controls DX Models See Section 6 4 6 4 Description Of Controls DX Models See Section 6 3 SECTION 7 OPERATING AUXILIARY EQUIPMENT SECTION 8 MAINTENANCE 8 1 Routine Maintenance 8 2 Servicing Air Cleaner 8 3 Adjusting Engine Speed Honda Powered Units 8 4 Adjusting Engine Speed Kohler Powered Units SECTION 9 TROUBLESHOOTING SECTION 10 PARTS LIST 10 1 Recommended Spare Parts SECTION 11 ELECTRICAL DIAGRAMS SECTION 12 GENERATOR POWER GUIDELINES SECTION 13 STICK WELDING SMAW GUIDELINES COMPLETE PARTS LIST www MillerWelds com WARRANTY aomanoonooa n a krhwouw SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom_2007 04 A Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are sh
77. so engine speed re turns to idle speed after start up or after weld or generator load is removed 7 Weld Output Control i Set control at maximum for full generator power output at AC receptacles Use control to select weld amperage Control may be adjusted while welding To Set Weld Output Control Use table to determine correct size electrode for weld am perage Select electrode type and set control to corresponding amperage range on name plate Adjust control to obtain desired weld performance EXAMPLE Electrode Diameter 1 8 Electrode Type E 6013 Current Control Setting 90 120 A 8 Hourmeter Use hourmeter to help schedule routine main tenance Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4415 Page 25 IT Complete Parts List available at www MillerWelds com SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 Generator Power Panel Receptacles 1 99 30A o NEUTRAL BONDED TO FRAME NEUTRE RACCORDE AU BATI i nO 2 Y Cx Von J 240V 120v GND PE MADE IN EIA A APPLETON WI VP WF A 120v A If unit does not have GFCI recep tacles use GFCI protected exten sion cord I Generator power decreases as weld current increases Set Weld Output con
78. t it last FUEL can cause fire or explosion e Stop engine and let it cool off before checking or adding fuel e Do not add fuel while smoking or if unit is near any sparks or open flames Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Dispose of rags in a fireproof container Always keep nozzle in contact with tank when fueling MOVING PARTS can cause injury e Keep away from fans belts and rotors v e Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove doors panels covers or guards for maintenance and troubleshooting as necessary e To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall doors panels covers or guards when servicing is finished and before starting engine e Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting Block flywheel so that it will not turn while working on generator components HOT PARTS can cause severe burns Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns
79. teries 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused 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 Mill
80. trode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverters after stop ping engine e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding OM 4415 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby W
81. trol to maximum for full generator power output at AC receptacles 1 240V AC Receptacle RC1 RC1 supplies 60 Hz single phase power at weld power speed Maximum output is 6 kVA kW peak or 5 5 kVA kW continu ous 2 120V 20A AC Duplex Receptacle RC2 3 120V 20A AC Duplex Receptacle RC3 RC2 and RC3 supply 60 Hz single phase power at weld power speed Maximum output from RC2 or RC3 is 2 4 kVA kW NOTICE Do not parallel the two 120V du plex receptacles 4 Supplementary Protector CB1 CB1 protects the receptacles from over load If CB1 opens the receptacles do not work Move switch to the On position to re set 5 Supplementary Protectors CB2 CB3 CB2 protects RC2 and CBS protects RC3 from overload If the supplementary pro 218 611 B tector opens the receptacle does not work Press button to reset IF If supplementary protector continues to open contact Factory Authorized Service Agent Combined output of all receptacles limited to 5 5 kVA KW continuous rating of the generator See Section 12 Generator Power Guidelines EXAMPLE If 10 A is drawn from each 120 volt duplex receptacle only 13 A is avail able from the 240 V receptacle 2 x 120 V x 10 A 240 V x 13 A 5 5 kVA KW OM 4415 Page 26 I Complete Parts List available at www MillerWelds com SECTION 8 MAINTENANCE gt Follow the storage procedure in the engine owner s manual if the unit will not be used for an
82. umer l information contenue dans les normes de s curit num r es la section 2 7 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus particuli rementles enfants HN gt gt UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne compor tant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre Ne passe servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l ou on risque de tomber e S
83. ur les emp cher de tomber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pastenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenirle chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curit 2 3 Dangers existant en relation avec le moteur L EXPLOSION DE LA BATTERIE peu RENDRE AVEUGLE e Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une intervention sur la batterie Arr ter le moteur avant de d brancher ou de brancher les c bles de batterie e Eviter de provoquer des tincel
84. z ards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby n NOISE can damage hearing Noise from some processes or equipment can dam age hearing e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pres sure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical dam

Miller Electric 185 DX Welding System User Manual

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