Miller Electric 145 DX manual Troubleshooting, Welding, Generator Power, Trouble Remedy

Page 31

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 protector (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.

 

 

 

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Contents File Engine Drive OM-4417210 403CProcesses DescriptionFrom Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes 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 gravesLES Étincelles Volantes risquent de provoquer des blessures ’AIR Comprimé peut provoquer des blessures’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueBoulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone LE Soudage À L’ARC risque de provoquer des interférencesPour les moteurs à essence Pour les moteurs diesel− Definitions − SpecificationsSymbol Definitions Weld, Power, And Engine SpecificationsDimensions Dimensions, Weights, And Operating AnglesVolt-Ampere Curves Fuel Consumption Duty Cycle Generator Power Curve100% Duty Cycle at 80 Amperes CC/DC Installing Welding Generator − InstallationGrounding Generator To Truck Or Trailer Frame Fuel Valve Open valve Grounding Generator When Supplying Building SystemsEngine Prestart Checks − Standard Model 13 mm Full GasolineTools Needed 1/2 Connecting The Battery DX Models OnlyEngine Prestart Checks − DX Model + −350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Connecting To Weld Output TerminalsSelecting Weld Cable Sizes 150 ft 200 ft 250 ftMaterial Thickness Reference Chart Controls Standard Models See Section − Operating the Welding GeneratorStop engine and add oil if light goes on see Section Description Of Controls Standard Models See SectionTo Start Controls DX Models See Section Description Of Controls DX Models See Section − Operating Auxiliary Equipment Generator Power Panel ReceptaclesAC Receptacle RC1 Routine Maintenance − MaintenanceStop engine Servicing Air CleanerStandard Model Shown Stop engine. Close fuel valve Adjusting Engine Speed Standard Models OnlyTools Needed Weld/Power Speed Adjustment Adjusting Engine Speed DX Models OnlyIdle Speed Adjustment Welding − TroubleshootingTroubleshooting Generator PowerEngine Circuit Diagram For Standard Models − Electrical DiagramsCircuit Diagram for DX Models Selecting Equipment − Generator Power GuidelinesAmperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/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 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 PossibleWeld current starts when electrode touches work- piece Stick Welding Procedure− Stick Welding Smaw Guidelines Striking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping 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 − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Main Assembly Standard Model − Parts ListDia Part Description Quantity Mkgs 4546 51 41 Main Assembly DX ModelMain Assembly OM-4417 Your distributor also gives ServiceSupport 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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145 DX specifications

Miller Electric has established itself as a leading name in the welding industry, and the Miller Electric 145 DX and 145 are notable additions to its lineup of innovative welding machines. Designed to offer versatility and efficiency, these units cater to both novice welders and seasoned professionals seeking reliable equipment for various welding applications.

One of the key features of the Miller Electric 145 DX and 145 is their advanced welding technology. Both models utilize inverter technology, which allows for a compact design while delivering exceptional power. This inverter design not only increases efficiency but also reduces energy consumption, making it an environmentally friendly choice. The lightweight nature of these units makes them highly portable, allowing users to easily transport them to job sites or move them around the workshop.

The Miller Electric 145 DX model incorporates a digital interface that simplifies set-up and operation. This user-friendly digital display shows critical parameters such as voltage and amperage, helping the operator make quick adjustments on-the-fly for optimal results. The advanced Auto-Set feature adjusts the machine settings automatically based on the material thickness and type, significantly reducing the learning curve for inexperienced welders.

Both the 145 DX and 145 models can handle a variety of welding processes, including MIG and TIG welding. This versatility makes them suitable for a wide range of applications, from automotive repair and fabrication to metal sculpture and DIY projects. The machines are capable of welding aluminum, stainless steel, and mild steel with ease, providing excellent penetration and bead appearance.

Another noteworthy characteristic of the Miller Electric 145 series is their reliability and durability. Designed with robust components that can withstand challenging working environments, these machines are built to last. The thermal overload protection feature ensures the units do not overheat, safeguarding the internal components and ensuring a longer operational life.

In summary, the Miller Electric 145 DX and 145 stand out in the welding equipment market due to their advanced inverter technology, user-friendly digital interfaces, versatile capabilities, and durability. They are ideal choices for anyone looking to elevate their welding experience, delivering consistent and reliable performance across a variety of projects.
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