Miller Electric Renegade 180 manual From Miller to You

Page 2

Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Miller Electric manufactures a full line

of welders and welding related equipment. For information on other quality Miller

products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 2005−04

Working as hard as you do

−every power source from Miller is backed by the most hassle-free warranty in the business.

Image 2

Contents Description OM-228 042BProcesses File Engine DriveFrom Miller to You Table of Contents − Maintenance 10-1Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosionEngine Hazards Compressed Air HazardsFire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation Indique des instructions spécifiquesLE 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 LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures ’EMPLOI Excessif peutInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité Weld, Power, And Engine Specifications − SpecificationsSymbol Definitions − DefinitionsOptional Lifting Eye Weight Rating Gun SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere CurvesPower Source Duty Cycle Fuel ConsumptionVolts Generator Power CurveGun Duty Cycle And Overheating AC AmperesMovement − InstallationInstalling Welding Generator Airflow ClearanceGrounding Generator When Supplying Building Systems Use ground device as stated in electrical codes+ − Connecting The Battery Electric Start Models OnlyEngine Prestart Checks OilInstalling Welding Gun Work Cable Routing Inside UnitWeld Process/Polarity Table Changing Weld PolarityThis unit can provide weld out Connecting Single−Phase, 230 Volt AC Utility Input PowerShown with optional cylinder rack When a slight force is needed to turn spool, tension is set Electrical Service GuideInstalling Wire Spool And Adjusting Hub Tension AdapterWeld Position Tools Needed 150 mm 030/.035 Groove Stamped Stamped .030/.035 Tighten Pressure Indicator ScaleThreading The Welding Gun Wood − Operating the Welding Generator Controls See SectionTo Stop Description Of Controls See SectionTo Start Weld Parameter Chart Stainless Steel And 100% CO2 Weld Parameters 20 ga 18 ga 16 ga 14 ga− Operating Auxiliary Equipment Generator Power Panel ReceptaclesGenerator power decreases as weld current increases − Maintenance Power Source Routine MaintenanceDrive Motor Protection Gun Routine MaintenanceWelding Power Source Overload Protection Tip Saver/Short Circuit ProtectionReplacing Gun Contact Tip Changing Drive Roll Or Wire Inlet GuideTurn Off power before replacing contact tip Turn off welding power source/wire feeder Maintaining GunReplacing Switch And/Or Head Tube Tools Needed 19 mmDo not wash paper element or clean with compressed air Servicing Air CleanerPrecleaner Paper Element Standard Model Shown Stop engineAdjusting Engine Speed Stop engine. Close fuel valveGenerator Power − TroubleshootingTroubleshooting WeldingDoes not run Wire FeederEngine Recommended Spare Parts − Parts ListRecommended Spare Parts − Electrical Diagrams OM-217 454Typical MIG Process Connections Regulator Flowmeter Wire Feeder Power Source Shielding Gas− MIG Welding Gmaw Guidelines Gun Work Clamp WorkpieceWire Suggested Wire Speed Typical MIG Process Control SettingsThese settings are guidelines only. Material Material thickness determines weld parametersTioned correctly on seam Nozzle, and tip of wire is posiHolding And Positioning Welding Gun Groove WeldsElectrode Extensions Stickout Conditions That Affect Weld Bead ShapeGun Angles And Weld Bead Profiles Fillet Weld Electrode Extension StickoutGun Movement During Welding Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Possible Causes Corrective Actions Troubleshooting − Excessive SpatterTroubleshooting − Porosity Troubleshooting − Incomplete Fusion Troubleshooting − Excessive Penetration12-11 Troubleshooting − Lack Of Penetration Troubleshooting − Distortion 12-13 Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Flat & Horizontal1 Fillet Common MIG Shielding GasesApplication Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Industrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Cord Lengths for 240 Volt LoadsSOCKET/WRENCH Selection Table Standard Metric Support ServiceYour distributor also gives For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s