Miller Electric 185 DX manual Connecting To Weld Output Terminals, Selecting Weld Cable Sizes

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5-6. Connecting To Weld Output Terminals

2

6

3

Do not place anything between weld cable terminal and copper bar.

4

5

.Complete Parts List available at www.MillerWelds.com

1Positive (+) Weld Output Terminal

2Negative (−) Weld Output Terminal

For Direct Current Electrode Posi- tive (DCEP), connect work cable to

1Negative (−) terminal and electrode holder to Positive (+) terminal.

For Direct Current Electrode nega- tive (DCEN), reverse cable con- nections.

Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine.

3Weld Output Terminal

4Supplied Weld Output Terminal Nut

5Weld Cable Terminal

6Copper 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: 3/4 in

Correct Installation

Incorrect Installation

803 596−B / 803 778-A

5-7. Selecting Weld Cable Sizes*

Weld Output

Terminals

Stop engine before connecting to weld output terminals.

Do not use worn, dam- aged, undersized, or poorly spliced cables.

 

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

 

 

 

Not Exceeding***

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100 ft (30 m) or Less

150 ft

200 ft

250 ft

300 ft

 

350 ft

400 ft

 

(45 m)

(60 m)

(70 m)

(90 m)

 

(105 m)

(120 m)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Welding

10 − 60%

60 − 100%

 

 

 

 

 

 

 

Duty

Duty

 

10 − 100% Duty Cycle

 

 

Amperes

 

 

 

Cycle

Cycle

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100

4 (20)

4 (20)

4 (20)

3 (30)

2 (35)

1 (50)

 

1/0 (60)

1/0 (60)

 

 

 

 

 

 

 

 

 

 

150

3 (30)

3 (30)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

 

3/0 (95)

3/0 (95)

 

 

 

 

 

 

 

 

 

 

200

3 (30)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

 

4/0 (120)

4/0 (120)

 

 

 

 

 

 

 

 

 

 

250

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

 

2 ea. 2/0

2 ea. 2/0

 

(2x70)

(2x70)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

300

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2 ea. 2/0

 

2 ea. 3/0

2 ea. 3/0

(2x70)

 

(2x95)

(2x95)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*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.

( ) = mm2 for metric useS-0007-F

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

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Contents OM-4415 ProcessesDescription File Engine DriveFrom Miller to You Table of Contents Page Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer DES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peuDES Organes Mobiles peuvent pro voquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF − Specifications Symbol DefinitionsWeld, Power, And Engine Specifications − DefinitionsDimensions, Weights, And Operating Angles DimensionsDuty Cycle 100% Duty Cycle at 100 Amperes CC/DCVolt-Ampere Curves Standard Model Honda EngineDX Model Kohler Engine Auxiliary Power Standard Model Honda Engine Auxiliary Power DX Model Kohler EngineFuel Consumption Curves Generator Power Curves Power Output Standard Model Honda EnginePower Output DX Model Kohler Engine − Installation Installing Welding GeneratorMovement HazardsGrounding Generator When Supplying Building Systems Engine Prestart Checks − Standard Model13 mm Full Gasoline Fuel Valve Open valveEngine Prestart Checks − DX Model + −Connect negative − cable last Tools Needed 1/2Connecting To Weld Output Terminals Stop engine before connecting to weld output terminalsSelecting Weld Cable Sizes 150 ft 200 ft 250 ftOM-4415 − Operating the Welding Generator Controls Standard Models See SectionTurn Engine switch to Off Description Of Controls Standard Models See SectionTo Start To StopControls DX Models See Section Description Of Controls DX Models See Section Generator Power Panel Receptacles − Operating Auxiliary Equipment− Maintenance Routine MaintenanceServicing Air Cleaner Precleaner Paper ElementStop engine Standard Model ShownAdjusting Engine Speed Honda-Powered Units Weld/Power Speed AdjustmentIdle Speed Adjustment Stop Engine CloseAdjusting Engine Speed Kohler−Powered Units Stop engine. Close fuel valveTools Needed − Troubleshooting TroubleshootingGenerator Power WeldingEngine − Parts List Recommended Spare PartsRecommended Spare Parts − Electrical Diagrams Circuit Diagram For Standard ModelsCircuit Diagram for DX Models − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Approximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-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 Cord Lengths for 120 Volt LoadsCurrent Load Watts Amperes Cord Lengths for 240 Volt LoadsStick Welding Procedure − Stick Welding Smaw GuidelinesElectrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingButt Joints Lap JointTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective ActionsTroubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Service Your distributor also givesSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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