Miller Electric 250 manual Generator Power Guidelines, Selecting Equipment

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SECTION 14 − GENERATOR POWER GUIDELINES

.The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.

14-1. Selecting Equipment

1

2

1Generator Power Receptacles − Neutral Bonded To Frame

23-Prong Plug From Case Grounded Equipment

32-Prong Plug From Double Insulated Equipment

.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.

3

OR

gen_pwr 2007−04 − Ref. ST-159 730 / ST-800 577

14-2. Grounding Generator To Truck Or Trailer Frame

! Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards.

! Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators.

		1	Equipment Grounding
			Terminal (On Front Panel)
		2	Grounding Cable (Not
	1		Supplied)
	1	3	Metal Vehicle Frame
		3	Metal Vehicle Frame
GND/PE	2	Connect cable from equipment
		ground terminal to metal vehicle
		frame. Use #10 AWG or larger
		insulated copper wire.

3	.

!

Electrically bond generator

frame to vehicle frame by met- al-to-metal contact.

Bed liners, shipping skids, and some running gear insu- late the welding generator from the vehicle frame. Al- ways connect a ground wire from the generator equip- ment grounding terminal to bare metal on the vehicle frame as shown.

! If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord.

S-0854

OM-217 455 Page 51

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Contents 2007−05−21 OM-217 455HFile Engine Drive Visit our website atFrom Miller to You Table of Contents 13-5 13-213-3 13-4HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationIndique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLES 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 ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresEn ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMF− Definitions − SpecificationsSymbol Definitions Weld, Power, and Engine SpecificationsDimensions For Units With Optional Running Gear Dimensions, Weights, and Operating AnglesDimensions Mounting − InstallationInstalling Welding Generator Vehicle frame. Always connect a ground wireStop engine and let cool Installing Exhaust PipeConnecting the Battery + −Overview And Engine Prestart Checks Daily pre-start checks Engine Left Side Engine Right SideStarting engine for the first time Run-in period first 100 hoursTools Needed Do not place Connecting to Weld Output TerminalsCorrect Installation Work Weld Output TerminalSelecting Weld Cable Sizes Do not use glow plugs longer than 20 seconds Engine Control SwitchesPlace switch in Run position to operate most MIG equipment − Operating the Welding GeneratorWeld Output Controls Work Clamp Electrode Holder Typical Stick Welding Connections And Control SettingsTypical Settings For 7018 1/8 Electrode Stop engineSet Weld Process Selector switch to Wire − position Dcen Typical MIG Welding Connections And SettingsSet Weld Process Selector switch to Wire + Dcep position Set Weld Process Selector switch to Wire + positionTools Needed 3/4 Work Not Used To Work Left Side View To verify Gfci is working properly Generator Power Receptacles− Operating Auxiliary Equipment At least once a month, run engine atSimultaneous 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 Damage when determining whether Cleaner or with dirty element. EngineMent is not covered by the warranty Air cleaner primary element canChecking Fuel Solenoid Adjusting Engine SpeedAdjusting Fuel Solenoid Position Stop screw is factory-set and should not be adjustedCheck for non-binding Adjusting Throttle SolenoidChecking Throttle Solenoid 16 mmAdjusting Idle Speed Making Engine Speed AdjustmentsAdjusting Weld/Power Speed Supplementary Protector CB8 Overload ProtectionComponent Panel Stop engine Fuse F1Trouble Remedy Troubleshooting TablesGenerator Power WeldingEngine Maintenance Display ActionCurrent transformer CT1, and throttle solenoid TS1 − Parts ListRecommended Spare Parts Recommended Spare PartsCircuit Diagram For Welding Generator − Electrical Diagrams228 719-B OM-217 455 231 607-B Run-In And Wetstacking − RUN-IN and WetstackingIdle − Performance DataFuel Consumption Curves US Gal./HrAC Amperes At 120 Volts Generator Power CurveDuty Cycle 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 Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codesFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical 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 10-30 9090 End View of Work Angle Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode HolderElectrode Movement During Welding Conditions That Affect Weld Bead Shape16 in 30 1.6 mm Tack Welds Butt JointsLap Joint Tee JointPossible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld TestTroubleshooting − 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 Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact