Miller Electric Renegade 180 manual Table of Contents

Page 3

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

1

1-1.

Symbol Usage

1

1-2.

Arc Welding Hazards

1

1-3.

Engine Hazards

3

1-4.

Compressed Air Hazards

3

1-5. Additional Symbols For Installation, Operation, And Maintenance

4

1-6. California Proposition 65 Warnings

5

1-7.

Principal Safety Standards

5

1-8.

EMF Information

5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

6

2-1.

Signification des symboles

6

2-2.

Dangers relatifs au soudage à l’arc

6

2-3.

Dangers existant en relation avec le moteur

8

2-4.

Dangers liés à l’air comprimé

9

2-5.

Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

9

2-6.

Proposition californienne 65 Avertissements

11

2-7.

Principales normes de sécurité

11

2-8.

Information EMF

11

SECTION 3 − DEFINITIONS

12

SECTION 4 − SPECIFICATIONS

12

4-1.

Description

12

4-2.

Weld, Power, And Engine Specifications

12

4-3.

Gun Specifications

13

4-4.

Dimensions, Weights, And Operating Angles

13

4-5.

Volt-Ampere Curves

13

4-6.

Fuel Consumption

14

4-7. Power Source Duty Cycle

14

4-8. Gun Duty Cycle And Overheating

15

4-9.

Generator Power Curve

15

SECTION 5 − INSTALLATION

16

5-1.

Installing Welding Generator

16

5-2.

Grounding Generator When Supplying Building Systems

17

5-3.

Engine Prestart Checks

18

5-4.

Connecting The Battery (Electric Start Models Only)

18

5-5.

Installing Welding Gun

19

5-6. Work Cable Routing Inside Unit

19

5-7.

Weld Process/Polarity Table

20

5-8.

Changing Weld Polarity

20

5-9.

Connecting Single−Phase, 230 Volt AC Utility Input Power

21

5-10.

Electrical Service Guide

22

5-11.

Installing Wire Spool And Adjusting Hub Tension

22

5-12.

Threading The Welding Gun

24

SECTION 6 − OPERATING THE WELDING GENERATOR

26

6-1.

Controls (See Section 6-2)

26

6-2.

Description Of Controls (See Section 6-1)

27

6-3.

Weld Parameter Chart

28

6-4.

Stainless Steel And 100% CO2 Weld Parameters

29

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

30

7-1.

Generator Power Panel Receptacles

30

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Contents File Engine Drive OM-228 042BProcesses DescriptionFrom Miller to You Table of Contents 10-1 − MaintenanceHOT 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 InformationIndique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerDES 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 ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF − Definitions − SpecificationsSymbol Definitions Weld, Power, And Engine SpecificationsVolt-Ampere Curves Gun SpecificationsDimensions, Weights, And Operating Angles Optional Lifting Eye Weight RatingFuel Consumption Power Source Duty CycleAC Amperes Generator Power CurveGun Duty Cycle And Overheating VoltsAirflow Clearance − InstallationInstalling Welding Generator MovementUse ground device as stated in electrical codes Grounding Generator When Supplying Building SystemsOil Connecting The Battery Electric Start Models OnlyEngine Prestart Checks + −Work Cable Routing Inside Unit Installing Welding GunChanging Weld Polarity Weld Process/Polarity TableConnecting Single−Phase, 230 Volt AC Utility Input Power Shown with optional cylinder rackThis unit can provide weld out Adapter Electrical Service GuideInstalling Wire Spool And Adjusting Hub Tension When a slight force is needed to turn spool, tension is setWeld Position Stamped Stamped .030/.035 Tighten Pressure Indicator Scale Threading The Welding GunTools Needed 150 mm 030/.035 Groove Wood Controls See Section − Operating the Welding GeneratorDescription Of Controls See Section To StartTo Stop Weld Parameter Chart 20 ga 18 ga 16 ga 14 ga Stainless Steel And 100% CO2 Weld ParametersGenerator Power Panel Receptacles Generator power decreases as weld current increases− Operating Auxiliary Equipment Power Source Routine Maintenance − MaintenanceTip Saver/Short Circuit Protection Gun Routine MaintenanceWelding Power Source Overload Protection Drive Motor ProtectionChanging Drive Roll Or Wire Inlet Guide Turn Off power before replacing contact tipReplacing Gun Contact Tip Maintaining Gun Turn off welding power source/wire feederTools Needed 19 mm Replacing Switch And/Or Head TubeStandard Model Shown Stop engine Servicing Air CleanerPrecleaner Paper Element Do not wash paper element or clean with compressed airStop engine. Close fuel valve Adjusting Engine SpeedWelding − TroubleshootingTroubleshooting Generator PowerWire Feeder EngineDoes not run − Parts List Recommended Spare PartsRecommended Spare Parts OM-217 454 − Electrical DiagramsGun Work Clamp Workpiece Regulator Flowmeter Wire Feeder Power Source Shielding Gas− MIG Welding Gmaw Guidelines Typical MIG Process ConnectionsMaterial thickness determines weld parameters Typical MIG Process Control SettingsThese settings are guidelines only. Material Wire Suggested Wire SpeedGroove Welds Nozzle, and tip of wire is posiHolding And Positioning Welding Gun Tioned correctly on seamFillet Weld Electrode Extension Stickout Conditions That Affect Weld Bead ShapeGun Angles And Weld Bead Profiles Electrode Extensions StickoutPoor Weld Bead Characteristics Good Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Excessive Spatter Troubleshooting − PorosityPossible Causes Corrective Actions Troubleshooting − Excessive Penetration 12-11 Troubleshooting − Lack Of PenetrationTroubleshooting − Incomplete Fusion 12-13 Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Common MIG Shielding Gases ApplicationFlat & Horizontal1 Fillet − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame 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 AmperesSOCKET/WRENCH Selection Table Standard Metric Service Your distributor also givesSupport 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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