Miller Electric Miller DU-OP manual RUN-IN Procedure, Wetstacking, Ment damage may occur

Page 52

SECTION 10 − RUN-IN PROCEDURE

run_in3 8/01

10-1. Wetstacking

Y Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip-

 

 

 

ment damage may occur.

 

 

1

Welding Generator

 

 

Run diesel engines near rated volt-

 

2

age and current during run-in period

 

to properly seat piston rings and

 

 

 

 

prevent wetstacking. See name-

 

 

plate, rating label, or specifications

 

 

section in this manual to find rated

 

 

voltage and current.

 

 

. Do not idle engine longer than

 

 

 

necessary. Piston rings seat

 

 

 

faster if engine runs at weld/

 

 

 

power rpm, and the welding

 

 

 

generator is kept loaded during

 

 

 

run-in.

1

 

2

Engine Exhaust Pipe

 

 

Wetstacking is unburned fuel and

 

 

oil in the exhaust pipe and occurs

 

 

during run-in if the engine is run too

 

 

long at light load or idle rpm.

 

 

If exhaust pipe is coated with a wet,

 

 

black, tar-like substance, dry the

 

 

engine using one of the following

 

 

run-in procedures.

 

 

See the engine manual for addition-

 

 

al engine run-in information.

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Contents Processes DescriptionFile Engine Drive Visit our website at OM-494191 862Q SeptemberFrom Miller to You Table of Contents − Operating Auxiliary Equipment Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessures’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueLE Soudage À L’ARC risque de provoquer des interférences Pour les moteurs à essencePour les moteurs diesel Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphoneSymbols And Definitions − Definitions− Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles DescriptionAC Generator Power Fuel ConsumptionExceeding duty cycle can damage unit and void warranty Duty Cycle And OverheatingOverheating Reduce Duty Cycle MinutesCC/DC − Single Mode CC/DC − Dual ModeCV/DC Mode Volt-Ampere Curves− Installation Installing Welding GeneratorActivating The Dry Charge Battery If Applicable Connecting The BatteryDo not overfill battery cells For 30 MinutesInstalling Exhaust Pipe Engine Prestart ChecksStop engine and let cool FuelSafety Information For Connecting To Weld Output Terminals Weld Output TerminalsUnexpected Weld Output can cause injury or fire Welder a Left Side Welder B Right SideWelder a Left Side Do not exceed machine duty cycleStop engine Do not exceed machine duty cycle Connect electrode holder cables to Elec- trode receptaclesPlace optional Polarity switches in Re Verse position when using CV weld reWhen switch is in Straight position Switches are set correctly. See SectionConnect wire feeder cables to Negative − terminals Connect wire feeder cables to CV recep- taclesBe sure Process Selector switches are Place optional Polarity switch in Re Making Single Operator CC Weld Connections OM-494 Selecting Weld Cable Sizes 150 ft 200 ft 250 ft350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Put terminalsInstalling Ether Cylinder Optional Ether Starting Aid After installing cylinder, wait atRemote 14 Receptacle Information Socket InformationRemote 14 Receptacle Connections Dual Operator Operation− Operating the Welding Generator Engine ControlsSee -3for weld control descriptions If light goes on, stop engine and check engine beltWeld Controls See Section Do not switch under load or with out- put on Do not switch under loadWeld Control Descriptions See Section CV weld output for MIG is only availableGenerator power is not affected by weld output − Operating Auxiliary EquipmentVolt And 240 Volt Duplex Receptacles At least once a month, run engine at− Maintenance & Troubleshooting Routine MaintenanceMaintenance Label Servicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hoseServicing Fuel And Lubrication Systems Adjusting Engine Speed Weld/PowerServicing Optional Ether Starting Aid CylinderTo adjust belt tension Checking And Replacing Alternator BeltMax Tools Needed 11/16 Stop engine To check belt tensionResetting Fan Belt Safety Shutdown Stop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Optional Spark Arrestor MufflerChecking Generator Brushes Circuit Protection Thermostats TP3 And TP4 Internal − Not ShownTroubleshooting WeldingFactory Authorized Service Agent check main rectifier SR2 Factory Authorized Service Agent check main rectifier SR3Repair or replace wire feeder Formers T5 thru T10, and control board PC1 or PC5Generator Power EngineOM-494 − Electrical Diagrams Circuit Diagram For Welding Generator210 657-A Wetstacking − RUN-IN ProcedureMent damage may occur Run-In Procedure Using Load Bank 4exceed duty cycle or equip- ment damage may occurCheck oil level frequently dur Ing run-in add oil if neededRun-In Procedure Using Resistance Grid Procedure at less thanBank/grid From flammables− Generator Power Guidelines Has this symbolSelecting Equipment Grounding Generator To Truck Or Trailer FrameGrounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Use ground device as stated Electrical codesApproximate 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 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 96−SEE FIG 92 91 103 102 101 100 25−SEE FIG 9104748 57−SEE FIG 78−SEE FIG 76 75 Item Dia Part Description Quantity Mkgs 189 Front Panel Front Panel -1Item Side Control Panels − Welder B Right Side Shown Side Control Panels -1Item Side Control Panels Generator Rectifier Assembly OM-494 Page Your distributor also gives ServiceSupport 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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