Miller Electric 250 manual Weld Output Controls

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. A complete Parts List is available at www.MillerWelds.com

6-2. Weld Output Controls

1

2

3

Ref. 228 647-A

1Weld Process Selector Switch NOTICE − Do not switch while welding. Use switch to select type of weld output.

Wire (GMAW) Welding: Use a positive (+) position for Direct Current Electrode Positive (DCEP) and a negative (−) position for Direct Current Electrode Negative.

Stick (SMAW) and TIG (GTAW Welding): Use a positive (+) position for Direct Current Elec- trode Positive (DCEP) and a negative (−) posi- tion for Direct Current Electrode Negative. Use AC position for alternating current.

2 Coarse Range Switch

NOTICE − Do not switch while welding.

Use switch to select weld amperage range when Weld Process Selector switch is in Stick/ Tig position, or voltage range when switch is in Wire position.

.For best arc starts and when using weld

and generator power together, use a low Coarse Range setting with the Fine con- trol set at 7 or higher.

3 Fine Control

Use control to select weld amperage (Stick/ Tig) or voltage (Wire) within the range selected by the Coarse Range switch. Control may be adjusted while welding.

Set control at 10 for maximum generator power.

Weld output would be about 124 A DC based on control settings shown (80% of 60 to 140 A). Settings shown are typical for welding with a 7018 (1/8) electrode.

.See Sections 6-3thru 6-5for typical pro- cess connections and control settings.

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Contents File Engine Drive OM-217 455HVisit our website at 2007−05−21From Miller to You Table of Contents 13-3 13-213-4 13-5Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsBuildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosionCompressed Air Hazards Engine HazardsHOT Parts can cause burns and injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer Indique des instructions spécifiquesLES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion ’EXPLOSION DE LA Batterie peu LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent pro voquer des blessures ’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion DES Organes Mobiles peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutPrincipales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF En ce qui concerne les implants médicauxSymbol Definitions − SpecificationsWeld, Power, and Engine Specifications − DefinitionsDimensions For Units With Optional Running Gear Dimensions, Weights, and Operating AnglesDimensions Installing Welding Generator − InstallationVehicle frame. Always connect a ground wire MountingConnecting the Battery Installing Exhaust Pipe+ − Stop engine and let coolOverview And Engine Prestart Checks Starting engine for the first time Engine Left Side Engine Right SideRun-in period first 100 hours Daily pre-start checksCorrect Installation Connecting to Weld Output TerminalsWork Weld Output Terminal Tools Needed Do not placeSelecting Weld Cable Sizes Place switch in Run position to operate most MIG equipment Engine Control Switches− Operating the Welding Generator Do not use glow plugs longer than 20 secondsWeld Output Controls Typical Settings For 7018 1/8 Electrode Typical Stick Welding Connections And Control SettingsStop engine Work Clamp Electrode HolderSet Weld Process Selector switch to Wire + Dcep position Typical MIG Welding Connections And SettingsSet Weld Process Selector switch to Wire + position Set Weld Process Selector switch to Wire − position DcenTools Needed 3/4 Work Not Used To Work Left Side View − Operating Auxiliary Equipment Generator Power ReceptaclesAt least once a month, run engine at To verify Gfci is working properlySimultaneous Weld And Power Battery Charge Controls − Operating Optional Battery ChargerDetermining Battery Charging Current Battery Charge Cable Connections Minutes Battery Charging ProcedureStart Your Professional Welding Career Now Routine Maintenance − Maintenance and TroubleshootingStop engine and let cool Oil And Fuel Maintenance Label And Engine Maintenance Activities804 197-A / Ref 803 111-A / 227 Ment is not covered by the warranty Cleaner or with dirty element. EngineAir cleaner primary element can Damage when determining whetherAdjusting Fuel Solenoid Position Adjusting Engine SpeedStop screw is factory-set and should not be adjusted Checking Fuel SolenoidChecking Throttle Solenoid Adjusting Throttle Solenoid16 mm Check for non-bindingAdjusting Idle Speed Making Engine Speed AdjustmentsAdjusting Weld/Power Speed Component Panel Stop engine Overload ProtectionFuse F1 Supplementary Protector CB8Generator Power Troubleshooting TablesWelding Trouble RemedyEngine Maintenance Display ActionRecommended Spare Parts − Parts ListRecommended Spare Parts Current transformer CT1, and throttle solenoid TS1Circuit Diagram For Welding Generator − Electrical Diagrams228 719-B OM-217 455 231 607-B Run-In And Wetstacking − RUN-IN and WetstackingFuel Consumption Curves − Performance DataUS Gal./Hr IdleDuty Cycle Generator Power CurveVolts AC Amperes At 120 VoltsDC Amps CC/AC Stick Mode AC Volts Stick Mode Volt-Ampere CurvesAC Amps DC Amps MIG Mode Volt-Ampere CurveSelecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsUse ground device as stated in electrical codes Amperes x Volts = WattsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Weld current starts when electrode touches work- piece Stick Welding Procedure− Stick Welding Smaw Guidelines Striking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping Technique Good Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleElectrode Movement During Welding Conditions That Affect Weld Bead ShapeLap Joint Butt JointsTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Excessive Spatter Troubleshooting − PorosityWeld Test Possible Causes Corrective ActionsTroubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Work like a Pro Your distributor also gives ServiceSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s