Miller Electric 230Volt User manual

Miller Electric 230Volt User manual
PipePro 304
Issued March 2006 • Index No. ED/10.6
™
Quick
Specs
Diesel Engine-Driven
Welder/Generator
Industrial Applications
Processes
Fabrication
Structural Steel Work
Cross-Country Pipe Welding
Process Plant Piping
Repair
Power Generation
MIG (GMAW) and Pulsed MIG (GMAW-P)*
Flux Cored (FCAW)
Stick (SMAW)
DC TIG (GTAW)
Air Carbon Arc (CAC-A) Cutting and Gouging
(thru 1/4 in carbons)
Air Plasma Cutting and Gouging
with Optional Spectrum Models
*with Optima Control
Output Range
CC/DC 5–400 A
CV/DC 10–34 V
Weld Output Rated at 104˚ F (40˚ C)
CC/DC and CV/DC: 300 A at 32 Volts,
60% Duty Cycle
Generator Power Rated at 104˚ F (40˚ C)
12,000 Watts, 1 or 3 phase
Weight
910 lb (412 kg)
The Power of Blue .
®
Excellent multiprocess arc performance. Stick welding (uphill
and downhill) is superior with excellent control on the bead
(root), hot pass, fill and cap. The DIG control changes a soft arc
to a stiff forceful arc that prevents electrode sticking. Lift-Arc™
TIG allows DC welding without the use of an HF unit for x-ray
quality starts. The MIG arc will run short arc, globular, spray,
and pulsed spray modes with excellent results using any wire
or flux core in the field. Inductance
control customizes the puddle for
maximum performance.
26-HP, 3-cylinder Kubota diesel engine provides automatic
engine shutdown to protect the engine from failure due to low
oil pressure or high coolant temperature.
Lightweight design and compact size allows a
driver to see over machine when mounted on a
truck bed. Fits sideways in a standard pickup.
Dual digital weld ammeter
and voltmeter are standard.
Amps or volts can be preset
using the weld meters.
Toolless top and side engine access
allows easy and faster maintenance
with little clearance space needed.
Cold weather starting aids
such as standard glow plugs
and block heater ensure
easy starts.
WELD AT IDLE — when more
power is required the machine
automatically goes to high speed
without a change in the arc. Idles
with up to 5 kW of weld power
(225 A at 23 V, 170 A at 30 V).
Dual power option (Patented)
uses 230 volt single- or threephase electric input power,
eliminating fuel cost, noise,
engine wear and emissions.
12,000 watts of voltage-regulated singleand three-phase generator power allows
electric welders and plasma cutters to be
plugged into the unit allowing multiple
arcs to be run at the same time.
Low noise operation allows for
better work site communication
and safety. 72 db at 7 m
(no load — idle), 78 db at 7 m
(full load — high speed).
Welder/generator is warranted for 3 years, parts and labor.
Engine is warranted separately by the engine manufacturer.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
(Subject to change without notice.)
Welding
Mode
Max.
Open-Circuit
Voltage
Rated Weld
Output at 32 V at
60% Duty Cycle*
Output
Range
CC/DC
95
300 A
5 – 400 A
CV/DC
95
300 A
10 – 34 V
Net
Weight
Generator Power
Dimensions
1-phase: 12 kVA/KW, 100/50 A, 120/240 VAC, 60 Hz
3-phase: 12 kVA/KW, 30 A, 240 VAC, 60 Hz
H: 30 in (762 mm)
W: 24 in (610 mm)
D: 59-1/2 in (1511 mm)
12 kVA/KW shared by all receptacles simultaneously
910 lb**
(412 kg)
*Rated output tested at 104° F (40° C). **Additional 99 lb (45 kg) when tank is full.
Engine Specifications
(Subject to change without notice.)
Engine Brand
Horsepower (HP)
Type
Weld Speed
Idle Speed
Fuel
Capacity
Oil
Capacity
High Coolant Temp/
Low Oil Pressure Shutdown
Kubota DH905
2-year limited
North American
Manufacturer
Warranty
26 at 3600 RPM
3-cylinder,
industrial,
liquid-cooled
diesel
3600 RPM
2525 RPM
13 gal (49 L)
5.4 qt (5.1 L)
Standard
Control Panel
11
1
2
12
3
4
5
13
14
15
6
7
16
17
8
18
9
19
10
1.
2.
3.
4.
5.
6.
7.
8.
Fuel Gauge
Engine Hour Meter
Battery Charging Light
Engine Oil Pressure Light
Engine Temperature Light
Glow Plug Switch
Engine Control Switch
Circuit breaker for 240 VAC, 50 A,
1-Phase Receptacle
9. 240 VAC, 50 A, 1-Phase,
Full KVA Receptacle
10.120 VAC, 20 A, Duplex Receptacles
11.Weld Voltmeter
2
12.Weld Ammeter
13.Voltage/Amperage
Adjustment Control
14.Mode Switch
15.Voltage/Amperage Control Switch
16.DIG/Inductance Control
17.Remote 14 Receptacle
18.240 VAC, 30 A, 3-Phase,
Full KVA Receptacle
19.Circuit breaker for 240 VAC, 30 A,
3-Phase Receptacle
Performance Data
DUTY CYCLE CHART
FUEL CONSUMPTION
600
1.75
500
5.67
1.25
1.50
4.73
1.04
1.25
3.78
0.83
1.00
2.84
0.62
0.75
1.98
0.40
0.50
0.95
0.21 0.25
0
0
0
U.S. GAL/HR.
2.00
1.46
IMP. GAL/HR.
1.70
6.62
LITERS/HR.
7.57
WELDING AMPERES
HIGH SPEED
LOW SPEED
IDLE
0
50
100
150
200
250
300
350
400
DC POWER AMPS AT 100% DUTY CYCLE
0
1
2
4
6
8
10
400
ENGINE/THREE-PHASE
300
SINGLE-PHASE
200
150
100
0
10
15
20
25
30
40
50
60 70 80 90100
% DUTY CYCLE
12
POWER KVA AT 100% DUTY CYCLE
Genuine Miller Options
Dual Power Option (Patented)
Allows the PipePro 304 to operate independently
of the engine using 230 volt single- or threephase electric input power. Eliminates fuel cost,
noise, engine wear and emissions. Plug #197 355
for dual power included (cord not included).
1
OFF
2
3
Note: Available as factory option. Dual power field option
(#195 275) effective with serial #LC649059. Field option
(#194 715) restricted to PipePro 304 units with serial
#LA062611 through #LC649058.
Specifications
1. 30 A Circuit Breaker
2. 3-Phase, 230 VAC Input Power Plug
3. Power Selector Switch
(Subject to change without notice.)
Heavy Industrial
Rated Weld Output
at 60% Duty Cycle
Voltage Range
in CV Mode
Amperage Range
in CC Mode
Max. OpenCircuit Voltage
RMS Amps Input at Rated Load Output, 60 Hz
3-Phase at NEMA Load Voltages and Class I Rating
230 V
KVA
KW
300 A at 32 VDC, 3-Phase
10 – 34 V
5 – 400 A
95 VDC
30.5
12.2
11.6
47.4
11.3
7.6
225 A at 29 VDC, 1-Phase
Lockable Flame Arrestor
Fuel Cap
#043 947 Field
Spark Arrestor Kit
#194 871 Field
Full KVA Plug Kit #119 172 Field
240/120 VAC single-phase, 50 amp plug
(NEMA 14-50P) to fit full KVA receptacle.
Three-Phase Full KVA Plug Kit
#007 470 Field
240 VAC three-phase, 30 amp plug
(NEMA L15-30P) to fit KVA receptacle.
3
Genuine Miller Accessories
Plasma Cutters
Protective Cover
#195 125 Blue, with Miller logo
Attractive, waterproof cover resists stains
and mildew, and protects the finish of
your welder.
Spectrum® 625 #907 058
Economical plasma cutting system
rated to cut 7/8 in. See Lit. Index
No. PC/9.5.
MIG/Flux Cored Welding
SuitCase™ 8VS Wire Feeder #194 890
SuitCase™ X-TREME™ 12VS Wire Feeder
#195 500
Lightweight, portable, voltage-sensing
wire feeders include secondary contactor
and gas valve. Require drive roll kit.
See Lit. Index No. M/6.4, M/6.41.
Multiple Operator Welding
XMT® 304 #903 471
The XMT 304 CC/CV multiprocess power
source can be run off the machine’s
generator to provide two arcs with only one
engine. The XMT combines the advantages
of inverter-based design with the built-in
features of a high-end MIG machine. At
only 76 lb (34.5 kg) it’s portable enough to
take anywhere. See Lit. Index No. DC/18.8.
Spectrum 2050 #903 777-01-2
Portable, easy-to-carry unit is an excellent
choice for cutting jobs up to 3/4 in.
See Lit. Index No. PC/7.0.
CST™ 280
#907 244 220-230/460–575 VAC,
50/60 Hz with Dinse-style connectors
#907 244-01-1 220-230/460–575 VAC,
50/60 Hz with Tweco-style connectors
#907 251 208-230/400–460 VAC,
50/60 Hz with Dinse-style connectors
#907 251-01-1 208-230/400–460 VAC,
50/60 Hz with Tweco-style connectors
The CST 280 CC/DC power source can be
run off the machine’s generator to provide
two arcs with only one engine. At only 41 lb
(18.6 kg), it is portable enough to take
anywhere. See Lit. Index No. DC/29.55.
4
SuitCase™ 8RC Wire Feeder #194 938
SuitCase™ 12RC Wire Feeder #194 940
Lightweight, modular design and flexible
enough to run a variety of wires up to
.062 in diameter. Comes standard with
remote voltage control. See Lit. Index
No. M/6.5.
Spoolmatic® 30A #130 831
A 1-lb, air-cooled spool gun that extends
the weld process range by adding a handy
portable system for small wire MIG. Rated
200 A at 100% duty cycle. Includes 30 ft
(9.1 m) cable assembly. WC Control
required. See Lit. Index No. M/1.5.
Genuine Miller Accessories (continued)
MIG/Flux Cored Welding (continued)
Remote Controls and Switches
WC-24 Control #137 549
To be used with the Spoolmatic 30A.
XR Wire Feeders and Guns
Push-pull system designed to handle
difficult-to-feed soft alloy wires such as
aluminum. See Lit. Index No. M/1.7.
MIG (GMAW)/FCAW Guns
Miller produces a complete line of
dependable MIG guns. Check literature
for complete details. See Lit. Index
Nos. AY/16.0 and AY/17.0.
Optima™ MIG (GMAW) Pulse Control
#043 389
A multipurpose, microprocessor-based
pulse control for synergic MIG (wire
welding or GMAW), manual MIG pulsing
or standard MIG welding. Use this control
with the PipePro 304 and any Miller wire
feeder, including automatic feeders and
spool guns. Includes 25 ft (7.6 m) cord
with 14-pin plug.
Stick (SMAW) Welding
Weld Leads
#173 851 2/0, 350 A, 100% duty cycle,
50 ft (15.2 m) stinger, 50 ft (15.2 m)
ground
RFCS-14 HD Foot Control #194 744
For all Miller solid-state power sources
after serial number JK674521. This new
design increases stability with a larger
base and durability with a heavier cord.
Maximum flexibility is accomplished
with a reconfigurable cord that can exit
the front, back or either side of the pedal.
Foot pedal provides remote current and
contactor control. Includes 20 ft (6 m)
cord and 14-pin plug.
RHC-14 Hand Control #129 340
Miniature hand control for remote current
and contactor control. Dimensions: 4 x 4 x
3-1/4 in (102 x 102 x 82 mm). Includes
20 ft (6 m) cord and 14-pin plug.
RCC-14 Remote Contactor and
Current Control #151 086
Rotary-motion fingertip control. Fastens to
TIG torch using two Velcro strips. Allows
complete current and contactor control at
operator’s fingertips. Includes 28 ft (8.5 m)
cord and plug.
Extension Cords for 14-Pin
Remote Controls
#122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (22.9 m)
PRHC-14 Hand Control #195 511
For all solid-state power sources after
serial number JK674521. Complete current
or voltage control brings 120 volts GFCI
power to work area in a single cord.
Housed in a durable light aluminum case
and includes 125 ft (38 m) cord with plugs.
#043 952 2/0, 300 A, 100% duty cycle,
100 ft (30.5 m) stinger, 50 ft (15.2 m)
ground
#043 956 2/0, 250 A, 100% duty cycle,
100 ft (30.5 m) stinger, 100 ft (30.5 m)
ground
5
Genuine Miller Accessories
(Continued)
Trailers and Hitches
Lunette Eye 2-1/2 in (64 mm) #043 824
For use with 224 trailer.
Cable Tree #043 826
Provides an area to conveniently wrap weld
cables and extension cords. For use with
224 trailer.
HWY-224 Trailer #043 805
A 2650 lb (1202 kg) capacity highway
trailer. Welded steel tubing frame, heavyduty axle with roller bearing hubs and
leaf-spring suspension. The HWY-224
comes with jack stand, 2 in (50 mm)
ball hitch, fenders and lights.
Note: Trailer is shipped unassembled.
Trailer Specifications
Model
HWY-224
(Subject to change without notice.)
Gross Axle
Weight
Rating
Gross Vehicle
Weight Rating
Net
Payload
Height
of Bed
Road
Clearance
Track
(Center to
center of tires)
Standard Tires
(Standard rating
or P-size rating)
3500 lb
(1588 kg)
2960 lb
(1343 kg)
2650 lb
(1202 kg)
18-1/2 in
(470 mm)
7-1/2 in
(191 mm)
52 in
(1321 mm)
B-78-13C
Dimensions
Net
Weight
Length: 105-1/2 in (2680 mm)
Width: 61 in (1549 mm)*
355 lb
(161 kg)
*Width at outside of fenders.
Mounting Specifications
A
4 Holes
Front Panel End
G
B
C
D
E
F
6
A. 23-5/8 in (600 mm)
B. 21-1/2 in (546 mm)
C. 1 in (25 mm)
D. 15-5/8 in (397 mm)
E. 26-3/8 in (679 mm)
F. 58-3/4 in (1492 mm)
G. 13/32 in (10 mm) Dia.
Overall Dimensions
Height: 30 in (762 mm)
36 in (914 mm)
to top of exhaust
Width: 24 in (610 mm)
Depth: 59-1/2 in (1511 mm)
Typical Installations
Remote Control
PRHC-14
Stick Electrode
Stick (SMAW) Basic Equipment
PRHC-14 #195 511
Work
Stick Electrode
Multiple Operator
XMT 304
XMT 304 #903 471
CST 280 #907 244
#907 244-01-1
#907 251
#907 251-01-1
(See pg. 4 or Lit. Index No.
DC/29.55 for more information)
CST 280
Work
Stick Electrode
Work
Flux Cored (FCAW) Basic Equipment
SuitCase 8VS #194 890
SuitCase X-TREME 12VS #195 500
MIG or Flux Cored Gun
SuitCase 8VS,
X-TREME 12VS
Work
MIG (GMAW) Basic Equipment
SuitCase 8RC #194 938
SuitCase 12RC #194 940
Optima #043 389
SuitCase
8RC,12RC
(optional)
with Optima
MIG Gun
Work
with
Spoolmatic 30A
Gun
MIG (GMAW) Basic Equipment
Spoolmatic 30A #130 831
WC-24 #137 549
WC-24
Work
Cutting Torch
Plasma Basic Equipment
Spectrum
Work
7
Ordering Information
Power Source and Options
Stock No.
Description
PipePro™ 304
Dual Power Option
Lockable Flame Arrestor Fuel Cap
Full KVA Plug Kit
Three-Phase Full KVA Plug Kit
Spark Arrestor Kit
#903 731
#903 731-01-3
#195 275
#043 947
#119 172
#007 470
#194 871
CC/CV
CC/CV, Dual Power
Field
Field
Field
Field
Field
Accessories
Protective Cover
#195 125
Field. Blue, with Miller logo
#903 471
#907 244
#907 244-01-1
#907 251
#907 251-01-1
See Lit Index No. DC/18.8
220-230/460–575 VAC w/Dinse-style connectors. See Lit Index No. DC/29.55
220-230/460 – 575 VAC w/Tweco-style connectors. See Lit Index No. DC/29.55
208-230/400 – 460 VAC w/Dinse-style connectors. See Lit Index No. DC/29.55
208-230/400 – 460 VAC w/Tweco-style connectors. See Lit Index No. DC/29.55
#907 058
#903 777-01-2
See Lit Index No. PC/9.5
See Lit Index No. PC/7.0
#194 890
#195 500
#194 938
#194 940
#130 831
#137 549
#043 389
See Lit. Index No. M/6.4
See Lit. Index No. M/6.4
See Lit. Index No. M/6.5
See Lit. Index No. M/6.5
Air-cooled. See Lit Index No. M/1.5
Required for use with Spoolmatic 30A. See Lit Index No. M/1.5
See Lit Index No. M/1.7
See Lit Index Nos. M/10.0 and M/13.4
MIG (GMAW) Pulse Control. See Lit Index No. AY/16.0 and AY/17.0
#173 851
#043 952
#043 956
2/0, 350 A, 100% duty cycle, 50 ft (15.2 m) stinger, 50 ft (15.2 m) work cable
2/0, 300 A, 100% duty cycle, 100 ft (30.5 m) stinger, 50 ft (15.2 m) work cable
2/0, 250 A, 100% duty cycle, 100 ft (30.5 m) stinger, 100 ft (30.5 m) work cable
#194 744
#129 340
#151 086
#195 511
#122 973
#122 974
#122 975
Foot control
Hand control
Fingertip control
Hand control. 120 volts GFCI power
25 ft (7.6 m)
50 ft (15.2 m)
75 ft (22.9 m)
#043 805
#043 824
#043 826
For use with 224 trailer
For use with 224 trailer
Multiprocess Welding
XMT® 304 CC/CV
CST ™ 280 CC/DC
Plasma Cutters
Spectrum® 625
Spectrum® 2050
MIG/Flux Cored Welding
SuitCase™ 8VS
SuitCase™ X-TREME™ 12VS
SuitCase™ 8RC
SuitCase™ 12RC
Spoolmatic® 30A
WC-24 Control
XR™ Wire Feeders and Guns
MIG (GMAW)/Flux Cored (FCAW) Guns
Optima™
Stick
Weld Leads
Qty.
Stick Electrodes
Remote Controls and Switches
RFCS-14HD
RHC-14
RCC-14
PRHC-14
Extension Cords
Trailers and Hitches
HWY-224 Trailer
Lunette Eye 2-1/2 in (64 mm)
Cable Tree
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Price
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