RUN-IN Procedure, Wetstacking | Miller Electric Miller DU-OP

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
	2	to properly seat piston rings and
		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.

OM-494 Page 48

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

Contents

Processes DescriptionFile Engine Drive Visit our website at OM-494191 862Q September From Miller to You Table of Contents − Operating Auxiliary Equipment Symbol Usage Arc Welding Hazards Engine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interference Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereux LE 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’ouïe LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessures’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électrique LE Soudage À L’ARC risque de provoquer des interférences Pour les moteurs à essencePour les moteurs diesel Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone Symbols And Definitions − Definitions − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Description AC Generator Power Fuel Consumption Exceeding duty cycle can damage unit and void warranty Duty Cycle And OverheatingOverheating Reduce Duty Cycle Minutes CC/DC − Single Mode CC/DC − Dual ModeCV/DC Mode Volt-Ampere Curves − Installation Installing Welding Generator Activating The Dry Charge Battery If Applicable Connecting The BatteryDo not overfill battery cells For 30 Minutes Installing Exhaust Pipe Engine Prestart ChecksStop engine and let cool Fuel Safety Information For Connecting To Weld Output Terminals Weld Output TerminalsUnexpected Weld Output can cause injury or fire Welder a Left Side Welder B Right Side Welder a Left Side Do not exceed machine duty cycle Stop engine Do not exceed machine duty cycle Connect electrode holder cables to Elec- trode receptacles Place optional Polarity switches in Re Verse position when using CV weld reWhen switch is in Straight position Switches are set correctly. See Section Connect wire feeder cables to Negative − terminals Connect wire feeder cables to CV recep- tacles Be 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 terminals Installing Ether Cylinder Optional Ether Starting Aid After installing cylinder, wait atRemote 14 Receptacle Information Socket Information Remote 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 belt Weld 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 available Generator 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 Maintenance Maintenance Label Servicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hose Servicing Fuel And Lubrication Systems Adjusting Engine Speed Weld/PowerServicing Optional Ether Starting Aid Cylinder To adjust belt tension Checking And Replacing Alternator BeltMax Tools Needed 11/16 Stop engine To check belt tension Resetting 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 Shown Troubleshooting Welding Factory 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 PC5 Generator Power Engine OM-494 − Electrical Diagrams Circuit Diagram For Welding Generator 210 657-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 needed Run-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 Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Use ground device as stated Electrical codes Approximate 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 Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Power Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting Amperage Typical 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 910 4748 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