Installation, Installing Welding Generator | Miller Electric 250

.A complete Parts List is available at www.MillerWelds.com

SECTION 5 − INSTALLATION

5-1. Installing Welding Generator

Movement

! Do not lift unit from end.

OR

Location / Airflow Clearance

OR

18in

(460 mm)

	18 in
18 in	(460 mm)

	(460 mm)
	18 in	18 in
	18 in	(460 mm)
	(460 mm)	(460 mm)
	(460 mm)

Mounting

			OR
Inadequate support.
	! Do not use flexible mounts.		1
Grounding 2		! Bed liners, shipping skids, and some running
GND/PE	3	! Bed liners, shipping skids, and some running
GND/PE		gears insulate the welding generator from the
		gears insulate the welding generator from the
		vehicle frame. Always connect a ground wire
		from the generator equipment grounding termi-
		nal to bare metal on the vehicle frame as shown.

Electrically bond generator frame to vehicle frame by metal-to-metal contact.

! Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base.

! Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.

! Do not mount unit by support- ing the base only at the four mounting holes. Use cross- supports to adequately sup- port unit and prevent damage to base.

! Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards.

! If unit does not have GFCI re- ceptacles, use GFCI-protected extension cord.

NOTICE − Do not install unit where air flow is restricted or engine may over- heat.

Mounting:

1 Cross-Supports

Mount unit on flat surface or use cross-supports to support base.

Grounding:

2Equipment Grounding Terminal (On Front Panel)

3Grounding Cable (Not Supplied)

4Metal Vehicle Frame

Connect cable from equipment ground terminal to metal vehicle frame. Use #10 AWG or larger insu- lated copper wire.

4	install2 12/06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

OM-217 455 Page 14

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Miller Electric 250 manual Installation, Installing Welding Generator, Mounting, Do not use flexible mounts Grounding

Contents

Visit our website at OM-217 455HFile Engine Drive 2007−05−21 From Miller to You Table of Contents 13-4 13-213-3 13-5 Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burns ARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosion Engine Hazards Compressed Air Hazards Fire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injury EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interference UN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation Indique des instructions spécifiques DES 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 LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures ’EMPLOI Excessif peut Information EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité En ce qui concerne les implants médicaux Weld, Power, and Engine Specifications − SpecificationsSymbol Definitions − Definitions Dimensions, Weights, and Operating Angles Dimensions For Units With Optional Running GearDimensions Vehicle frame. Always connect a ground wire − InstallationInstalling Welding Generator Mounting + − Installing Exhaust PipeConnecting the Battery Stop engine and let cool Overview And Engine Prestart Checks Run-in period first 100 hours Engine Left Side Engine Right SideStarting engine for the first time Daily pre-start checks Work Weld Output Terminal Connecting to Weld Output TerminalsCorrect Installation Tools Needed Do not place Selecting Weld Cable Sizes − Operating the Welding Generator Engine Control SwitchesPlace switch in Run position to operate most MIG equipment Do not use glow plugs longer than 20 seconds Weld Output Controls Stop engine Typical Stick Welding Connections And Control SettingsTypical Settings For 7018 1/8 Electrode Work Clamp Electrode Holder Set Weld Process Selector switch to Wire + position Typical MIG Welding Connections And SettingsSet Weld Process Selector switch to Wire + Dcep position Set Weld Process Selector switch to Wire − position Dcen Tools Needed 3/4 Work Not Used To Work Left Side View At least once a month, run engine at Generator Power Receptacles− Operating Auxiliary Equipment To verify Gfci is working properly Simultaneous Weld And Power − Operating Optional Battery Charger Battery Charge ControlsDetermining Battery Charging Current Battery Charge Cable Connections Battery Charging Procedure Minutes Start Your Professional Welding Career Now − Maintenance and Troubleshooting Routine Maintenance Maintenance Label And Engine Maintenance Activities Stop engine and let cool Oil And Fuel 804 197-A / Ref 803 111-A / 227 Air cleaner primary element can Cleaner or with dirty element. EngineMent is not covered by the warranty Damage when determining whether Stop screw is factory-set and should not be adjusted Adjusting Engine SpeedAdjusting Fuel Solenoid Position Checking Fuel Solenoid 16 mm Adjusting Throttle SolenoidChecking Throttle Solenoid Check for non-binding Making Engine Speed Adjustments Adjusting Idle SpeedAdjusting Weld/Power Speed Fuse F1 Overload ProtectionComponent Panel Stop engine Supplementary Protector CB8 Welding Troubleshooting TablesGenerator Power Trouble Remedy Maintenance Display Action Engine Recommended Spare Parts − Parts ListRecommended Spare Parts Current transformer CT1, and throttle solenoid TS1 − Electrical Diagrams Circuit Diagram For Welding Generator 228 719-B OM-217 455 231 607-B − RUN-IN and Wetstacking Run-In And Wetstacking US Gal./Hr − Performance DataFuel Consumption Curves Idle Volts Generator Power CurveDuty Cycle AC Amperes At 120 Volts Stick Mode Volt-Ampere Curves DC Amps CC/AC Stick Mode AC VoltsAC Amps MIG Mode Volt-Ampere Curve DC Amps − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Use ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = Watts 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 Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Single-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 / Volts = Starting Amperage Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Stick Welding Procedure Weld current starts when electrode touches work- piece− Stick Welding Smaw Guidelines Electrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique Positioning Electrode Holder Poor Weld Bead CharacteristicsGood Weld Bead Characteristics 10-30 9090 End View of Work Angle Conditions That Affect Weld Bead Shape Electrode Movement During Welding Tee Joint Butt JointsLap Joint 16 in 30 1.6 mm Tack Welds Weld Test Troubleshooting − PorosityTroubleshooting − Excessive Spatter Possible Causes Corrective Actions Troubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Work like a Pro Service Your distributor also givesSupport 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