Miller Electric 185 DX manual Troubleshooting, Welding, Generator Power, Trouble Remedy

Page 35

. 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-

Be sure all equipment is disconnected from receptacles when starting unit.

put at ac receptacles.

 

 

 

 

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-

Check Weld Output control setting.

put okay at ac receptacles.

 

 

 

 

Check weld connections.

 

 

 

Have Factory Authorized 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 8-3or 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 8-3or 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 8-3or 8-4).

 

 

 

Check throttle/governor linkage for smooth, non-binding operation.

 

 

B. Generator Power

Trouble

Remedy

 

 

No output at generator power ac re-

Be sure all equipment is disconnected from receptacles when starting unit.

ceptacles; no weld output.

 

 

 

 

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-

Reset and check supplementary protectors (see Section 7-1).

ceptacles; weld output okay.

 

 

 

 

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

Check engine speed, and adjust if necessary (see Section 8-3or 8-4).

receptacles.

 

 

 

OM-4415 Page 31

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Contents File Engine Drive OM-4415Processes DescriptionFrom Miller to You Table of Contents Page HOT 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 InformationUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux DES Organes Mobiles peuvent pro voquer des blessures LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité − Definitions − SpecificationsSymbol Definitions Weld, Power, And Engine Specifications100% Duty Cycle at 100 Amperes CC/DC Dimensions, Weights, And Operating AnglesDimensions Duty CycleDX Model Kohler Engine Volt-Ampere CurvesStandard Model Honda Engine Fuel Consumption Curves Auxiliary Power Standard Model Honda EngineAuxiliary Power DX Model Kohler Engine Power Output DX Model Kohler Engine Generator Power CurvesPower Output Standard Model Honda Engine Hazards − InstallationInstalling Welding Generator MovementFuel Valve Open valve Grounding Generator When Supplying Building SystemsEngine Prestart Checks − Standard Model 13 mm Full GasolineTools Needed 1/2 Engine Prestart Checks − DX Model+ − Connect negative − cable last150 ft 200 ft 250 ft Connecting To Weld Output TerminalsStop engine before connecting to weld output terminals Selecting Weld Cable SizesOM-4415 Controls Standard Models See Section − Operating the Welding GeneratorTo Stop Turn Engine switch to OffDescription Of Controls Standard Models See Section To StartControls DX Models See Section Description Of Controls DX Models See Section − Operating Auxiliary Equipment Generator Power Panel ReceptaclesRoutine Maintenance − MaintenanceStandard Model Shown Servicing Air CleanerPrecleaner Paper Element Stop engineStop Engine Close Adjusting Engine Speed Honda-Powered UnitsWeld/Power Speed Adjustment Idle Speed AdjustmentTools Needed Adjusting Engine Speed Kohler−Powered UnitsStop engine. Close fuel valve Welding − TroubleshootingTroubleshooting Generator PowerEngine Recommended Spare Parts − Parts ListRecommended Spare Parts Circuit Diagram For Standard Models − Electrical DiagramsCircuit Diagram for DX Models Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment How Much Power Does Equipment Require? Grounding When Supplying Building SystemsFarm/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 Cord Lengths for 240 Volt Loads Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Current Load Watts Amperes− Stick Welding Smaw Guidelines Stick Welding ProcedureStriking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start 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 − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Support ServiceYour distributor also gives 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
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