Miller Electric Metro 250D manual Connecting to Weld Output Terminals, Selecting Weld Cable Sizes

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4.4Connecting to Weld Output Terminals

Ref. ST-158 936-D / Ref. ST-175 918-C

1 Positive (+) Weld Output

 

Tools Needed:

Terminal

 

 

3/4 in

2 Negative (−) Weld Output

 

 

 

Terminal

 

 

For Direct Current Electrode Positi-

 

 

ve (DCEP), connect work cable to

 

 

Negative (−) terminal and electrode

 

 

cable (Stick) or torch cable (TIG) to

 

 

Positive (+) terminal.

 

 

For Direct Current Electrode Nega-

 

 

tive (DCEN), reverse cable con-

1

2

nections.

 

 

If unit has optional polarity switch, connect work cable to Work terminal and electrode or torch cable to electrode terminal.

4.5Selecting Weld Cable Sizes

 

 

 

Total Cable (Copper) Length in Weld Circuit Not Exceeding

 

 

 

 

 

 

 

 

 

 

 

 

Welding

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)

Amperes

 

 

 

 

 

 

 

 

 

 

 

 

 

10 − 60%

60 − 100% Duty

 

 

10 − 100% Duty Cycle

 

 

 

Duty Cycle

Cycle

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100

4

4

 

4

3

2

1

1/0

1/0

 

 

 

 

 

 

 

 

 

 

150

3

3

 

2

1

1/0

2/0

3/0

3/0

 

 

 

 

 

 

 

 

 

 

200

3

2

 

1

1/0

2/0

3/0

4/0

4/0

 

 

 

 

 

 

 

 

 

 

250

2

1

 

1/0

2/0

3/0

4/0

2-2/0

2-2/0

 

 

 

 

 

 

 

 

 

 

300

1

1/0

 

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

 

 

 

 

 

 

 

 

 

 

350

1/0

2/0

 

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

 

 

 

 

 

 

 

 

 

 

400

1/0

2/0

 

3/0

4/0

2-2/0

2-3/0

2-4/0

2-4/0

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.

S-0007-D

OM-402

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Contents Description OM-402BProcesses From Miller to You Metro 250D Table of ContentsPage Arc Welding Hazards Safety Precautions − Read Before UsingSymbol Usage Engine Hazards Engine Heat can cause fire Battery Explosion can BlindMoving Parts can cause injury Engine Exhaust Gases can killARC Welding can cause interference Principal Safety StandardsEMF Information Radiation can cause interferenceLES Fumées ET LES GAZ peuvent être dangereux Signification des symbolesConsignes de sécurité − lire avant utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures gravesLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chaleur DU Moteur peut pro- voquer un incendieUNE Remorque QUI Bascule peut entraîner des blessures Principales normes de sécuritéInformation sur les champs électromagnétiques Électrostatiques peuvent endommager les circuits imprimésDefinitions Symbols and DefinitionsGeneral Precautionary Label Fan and Moving Parts Label Battery Charging LabelDiesel Fuel Label Hot Muffler Label− 50 h Std Falling Equipment LabelActivation Tag Manufacturer’s Rating Label Do Not Use Ether LabelVolt-Ampere Curve SpecificationsWeld, Power, and Engine Specifications Dimensions, Weights, and Operating AnglesDuty Cycle and Overheating Fuel ConsumptionLocation Grounding InstallationAC Auxiliary Power Curve Installing Welding GeneratorConnect negative − cable last Connecting Battery and Installing Exhaust PipeEngine Prestart Checks Stop engine10 − 60% 60 − 100% Duty 10 − 100% Duty Cycle Connecting to Weld Output TerminalsSelecting Weld Cable Sizes 100 ft 30 m or LessSocket Information Remote 14 Receptacle RC1 InformationRef. ST-158 Plug Using Idle Lock SwitchOperating the Welding Generator Front Panel ControlsRemote Amperage and Contactor Control Operating Auxiliary Equipment Auxiliary Power ReceptaclesMaintenance & Troubleshooting 100 Hrs Maintenance Changing Engine Oil and Oil Filter Changing Fuel Filters Servicing Air CleanerTo Clean air filter Do not clean housing with air hoseWeld/Power Speed Adjustment Adjusting Engine SpeedIdle Speed Adjustment Engine Control Circuit Weld And Auxiliary Power CircuitsRemote Control Circuit Overload ProtectionTrouble Remedy Welding TroubleshootingStop engine and let cool. Reinstall cleanout plug Servicing Optional Spark ArrestorEngine Troubleshooting Auxiliary Power TroubleshootingUle OM-402 Circuit Diagram for Welding Generator Electrical DiagramSC-181 Heavy loading during first Run-In ProcedureWetstacking Load Bank Run-In Procedure Using Load BankRun-In Procedure Using Resistance Grid Grounding Generator to Truck or Trailer Frame Auxiliary Power GuidelinesSelecting Equipment Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Farm/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 = Starting Amperage Volts Power Required to Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections to Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleMain Assembly Parts ListST-801 488-A PC6 11.1CB9 Panel, Front w/Components .1 Item CB5 11.2Generator .1 Item Diode Board Control Box w/Components .1 ItemOM-402 Page OM-402 Page Metro 250D Options and AccessoriesCall Miller for your local Miller distributor Miller Electric Mfg. Co Owner’s Record