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OM-262 506D 2015−02 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welder/Generator Big Blue 350 And 350X PipePro Series ® ® CAT, CAT CE, And Mitsubishi File: Engine Drive Visit our website at www.MillerWelds.com From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The Miller is the first welding parts list will then help you to decide the equipment manufacturer in exact part you may need to fix the problem. the U.S.A. to be registered to the ISO 9001:2000 Quality Warranty and service information for your System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Mil_Thank 2009−09 Working as hard as you do − every power source from Miller is backed by the most hassle-free warranty in the business. TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Volt-Ampere Curves For Models With CAT Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Volt-Ampere Curves For Models With Mitsubishi Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. CAT Engine Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Mitsubishi Engine Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Installing Welder/Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Engine General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Engine Fuel And Coolant Prestart Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. CAT Engine Oil Prestart Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Mitsubishi Engine Oil Prestart Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 3 3 4 6 6 6 7 7 7 9 10 11 13 13 13 14 14 16 18 18 18 18 18 19 20 21 22 22 23 24 24 25 26 27 27 28 28 29 29 30 30 TABLE OF CONTENTS SECTION 6 − OPERATING WELDER/GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Arc Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5. Low Open-Circuit Voltage (VRD) Switch Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7. Lift-Arc TIG With Auto-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10. Operating Optional Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Export Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. GFCI Receptacle Information, Resetting And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Maintenance Label (CAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Maintenance Label (Mitsubishi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12. Maintaining Stainless Steel (Models With Optional Package) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13. Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2. Run-In Procedure Using Load Bank Or Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPLETE PARTS LIST − Available at www.MillerWelds.com WARRANTY 32 32 33 34 35 36 36 37 38 39 40 41 41 42 43 44 44 45 46 46 47 47 48 48 49 50 52 52 52 53 55 55 56 60 60 61 62 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914, U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s). Product/Apparatus Identification: Product Big Blue 350X Pipe Pro Stock Number 907530 Council Directives: ·2006/95/EC Low Voltage ·2004/108/EC Electromagnetic Compatibility ·2011/65/EU Restriction of the use of certain Hazardous Substances in electrical and electronic equipment ·2000/14/EC & 2005/88/EC Outdoor Noise ·Notified Body: AV Technology; AVTECH House, Arkle Avenue; Stanley Green Trading Estate; Hand­ forth, Cheshire, SK93RW, United Kingdom ·Conformity Assessment Procedure Followed: Annex VI, 2000/14/EC ·Technical Document Holder: Manufacturer ·Notified Body Evaluation Report No: GB/1067/0551/04 ·Measured Sound Power level: 95 dB L WA ·Guaranteed Sound Power Level: 96 dB L WA ·Electric Power PeL : 11.9 kW Standards: • IEC 60974­1:2005 Arc welding equipment – Part 1: Welding power sources • IEC 60974­10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements Signatory: May 29, 2014 _____________________________________ ___________________________________________ David A. Werba Date of Declaration MANAGER, PRODUCT DESIGN COMPLIANCE 257583­B SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2013−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. NOTICE − Indicates statements not related to personal injury. Indicates special instructions. This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-7. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit. Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). Always verify the supply ground — check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When making input connections, attach proper grounding conductor first − double-check connections. Keep cords dry, free of oil and grease, and protected from hot metal and sparks. Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or repaired cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use. Use GFCI protection when operating auxiliary equipment. Do not test or reset GFCI receptacles at idle speed/low voltage or the GFCI will be damaged and not provide protection from electric shock caused by a ground fault. SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER stopping engine. Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts. HOT PARTS can burn. Do not touch hot parts bare handed. Allow cooling period before working on equipment. To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes. OM-262 506 Page 1 FLYING METAL or DIRT can injure eyes. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear approved safety glasses with side shields even under your welding helmet. FUMES AND hazardous. GASES can be Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. BUILDUP OF GAS can injure or kill. Shut off compressed gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator. ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash, glare, and sparks; warn others not to watch the arc. Wear body protection made from durable, flame-resistant material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Do not weld where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. OM-262 506 Page 2 Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards). Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline). Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear body protection made from durable, flame-resistant material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. Use only correct fuses or circuit breakers. Do not oversize or bypass them. Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise level is high. ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices. Wearers of Pacemakers and other Implanted Medical Devices should keep away. Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. CYLINDERS can explode if damaged. Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder — explosion will result. Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders. Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards. 1-3. Engine Hazards BATTERY EXPLOSION can injure. Always wear a face shield, rubber gloves, and protective clothing when working on a battery. Stop engine before disconnecting or connecting battery cables, battery charging cables (if applicable), or servicing battery. Do not allow tools to cause sparks when working on a battery. Do not use welder to charge batteries or jump start vehicles unless the unit has a battery charging feature designed for this purpose. Observe correct polarity (+ and −) on batteries. Disconnect negative (−) cable first and connect it last. Keep sparks, flames, cigarettes, and other ignition sources away from batteries. Batteries produce explosive gases during normal operation and when being charged. Follow battery manufacturer’s instructions when working on or near a battery. FUEL can cause fire or explosion. Stop engine and let it cool off before checking or adding fuel. Do not add fuel while smoking or if unit is near any sparks or open flames. Do not overfill tank — allow room for fuel to expand. Do not spill fuel. If fuel is spilled, clean up before starting engine. Dispose of rags in a fireproof container. Always keep nozzle in contact with tank when fueling. MOVING PARTS can injure. Keep away from moving parts such as fans, belts, and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Stop engine before installing or connecting unit. Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. To prevent accidental starting during servicing, disconnect negative (−) battery cable from battery. Keep hands, hair, loose clothing, and tools away from moving parts. Reinstall doors, panels, covers, or guards when servicing is finished and before starting engine. Before working on generator, remove spark plugs or injectors to keep engine from kicking back or starting. Block flywheel so that it will not turn while working on generator components. EXHAUST SPARKS can cause fire. Do not let engine exhaust sparks cause fire. Use approved engine exhaust spark arrestor in required areas — see applicable codes. HOT PARTS can burn. Do not touch hot parts bare handed. Allow cooling period before working on equipment. To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold to avoid scalding. Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements. Wear safety glasses and gloves and put a rag over radiator cap. Turn cap slightly and let pressure escape slowly before completely removing cap. Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER use inside a home or garage, EVEN IF doors and windows are open. Only use OUTSIDE and far away from windows, doors, and vents. BATTERY ACID can BURN SKIN and EYES. Do not tip battery. Replace damaged battery. Flush eyes and skin immediately with water. ENGINE HEAT can cause fire. Do not locate unit on, over, or near combustible surfaces or flammables. Keep exhaust and exhaust pipes way from flammables. 1-4. Compressed Air Hazards COMPRESSED AIR EQUIPMENT can injure or kill. Incorrect installation or operation of this unit could result in equipment failure and personal injury. Only qualified persons should install, operate, and service this unit according to its Owner’s Manual, industry standards, and national, state, and local codes. Do not exceed the rated output or capacity of the compressor or any equipment in the compressed air system. Design compressed air system so failure of any component will not put people or property at risk. Before working on compressed air system, turn off and lockout/ tagout unit, release pressure, and be sure air pressure cannot be accidentally applied. Do not work on compressed air system with unit running unless you are a qualified person and following the manufacturer’s instructions. Do not modify or alter compressor or manufacturer-supplied equipment. Do not disconnect, disable, or override any safety equipment in the compressed air system. Use only components and accessories approved by the manufacturer. Keep away from potential pinch points or crush points created by equipment connected to the compressed air system. Do not work under or around any equipment that is supported only by air pressure. Properly support equipment by mechanical means. OM-262 506 Page 3 HOT METAL from air arc cutting and gouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep extinguisher nearby. COMPRESSED AIR can injure or kill. Before working on compressed air system, turn off and lockout/tagout unit, release pressure, and be sure air pressure cannot be accidentally applied. Relieve pressure before disconnecting or connecting air lines. Check compressed air system components and all connections and hoses for damage, leaks, and wear before operating unit. Do not direct air stream toward self or others. Wear protective equipment such as safety glasses, hearing protection, leather gloves, heavy shirt and trousers, high shoes, and a cap when working on compressed air system. Use soapy water or an ultrasonic detector to search for leaks−−never use bare hands. Do not use equipment if leaks are found. Reinstall doors, panels, covers, or guards when servicing is finished and before starting unit. If ANY air is injected into the skin or body seek medical help immediately. BREATHING COMPRESSED AIR can injure or kill. Do not use compressed air for breathing. Use only for cutting, gouging, and tools. TRAPPED AIR PRESSURE AND WHIPPING HOSES can injure. Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill cap. MOVING PARTS can injure. Keep away from moving parts such as fans, belts and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Keep hands, hair, loose clothing, and tools away from moving parts. Before working on compressed air system, turn off and lockout/ tagout unit, release pressure, and be sure air pressure cannot be accidentally applied. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary. Reinstall doors, panels, covers, or guards when servicing is finished and before starting engine. HOT PARTS can burn. Do not touch hot compressor or air system parts. Allow cooling period before working on equipment. To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. READ INSTRUCTIONS. Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. Use only genuine replacement parts from the manufacturer. Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes. 1-5. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. Use lifting eye to lift unit and properly installed accessories only, NOT gas cylinders. Do not exceed maximum lift eye weight rating (see Specifications). Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. Keep equipment (cables and cords) away from moving vehicles when working from an aerial location. Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment. OM-262 506 Page 4 OVERHEATING can damage motors. Turn off or unplug equipment before starting or stopping engine. Do not let low voltage and frequency caused by low engine speed damage electric motors. Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable. FLYING SPARKS can injure. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. Sparks can cause fires — keep flammables away. MOVING PARTS can injure. Keep away from moving parts. Keep away from pinch points such as drive rolls. BATTERY CHARGING OUTPUT and BATTERY EXPLOSION can injure. STATIC (ESD) can damage PC boards. Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and boxes to store, move, or ship PC boards. Battery charging not present on all models. Always wear a face shield, rubber gloves, and protective clothing when working on a battery. Stop engine before disconnecting or connecting battery cables, battery charging cables (if applicable), or servicing battery. Do not allow tools to cause sparks when working on a battery. Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose. Observe correct polarity (+ and −) on batteries. Disconnect negative (−) cable first and connect it last. Keep sparks, flames, cigarettes, and other ignition sources away from batteries. Batteries produce explosive gases during normal operation and when being charged. Follow battery manufacturer’s instructions when working on or near a battery. Have only qualified persons do battery charging work. If battery is being removed from a vehicle for charging, disconnect negative (−) cable first and connect it last. To prevent an arc, make sure all accessories are off. Charge lead-acid batteries only. Do not use battery charger to supply power to an extra-low-voltage electrical system or to charge dry cell batteries. Do not charge a frozen battery. TILTING OF TRAILER can injure. Use tongue jack or blocks to support weight. Properly install welding generator onto trailer according to instructions supplied with trailer. READ INSTRUCTIONS. Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. Use only genuine replacement parts from the manufacturer. Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes. H.F. RADIATION can cause interference. Do not use damaged charging cables. Do not charge batteries in a closed area or where ventilation is restricted. Do not charge a battery that has loose terminals or one showing damage such as a cracked case or cover. Before charging battery, select correct charger voltage to match battery voltage. Set battery charging controls to the Off position before connecting to battery. Do not allow battery charging clips to touch each other. Keep charging cables away from vehicle hood, door, or moving parts. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. ARC WELDING can cause interference. WELDING WIRE can injure. Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. OVERUSE can cause OVERHEATING. Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. OM-262 506 Page 5 1-6. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. For Gasoline Engines: Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. For Diesel Engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-7. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org). Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.) OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814 (phone: 301-504-7923, website: www.cpsc.gov/cpscpub/pubs/portgen.pdf). Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH). 1-8. EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 1. Keep cables close together by twisting or taping them, or using a cable cover. 2. Do not place your body between welding cables. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. OM-262 506 Page 6 4. Keep head and trunk as far away from the equipment in the welding circuit as possible. 5. Connect work clamp to workpiece as close to the weld as possible. 6. Do not work next to, sit or lean on the welding power source. 7. Do not weld whilst carrying the welding power source or wire feeder. About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended. SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_rom_2013−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. NOTE − Indique des déclarations pas en relation avec des blessures personnelles. Indique des instructions spécifiques. Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger. 2-2. Dangers relatifs au soudage à l’arc Les symboles présentés ci-après sont utilisés tout au long du présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 2-7. Veuillez lire et respecter toutes ces normes de sécurité. L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées. Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants. UN CHOC ÉLECTRIQUE peut tuer. Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les circuits internes de l’appareil sont également sous tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un danger. Ne jamais toucher les pièces électriques sous tension. Porter des gants et des vêtements de protection secs ne comportant pas de trous. S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre. Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber. Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande. Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé. Des précautions de sécurité supplémentaires sont requises dans des environnements à risque comme: les endroits humides ou lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions assises, à genoux et allongées; ou quand il y a un risque important de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence: 1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un poste à souder manuel (électrode enrobée) DC, 3) un poste à souder manuel AC avec tension à vide réduite. Dans la plupart des cas, un poste courant continu de type CV est recommandé. Et, ne pas travailler seul! Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité). Installez, mettez à la terre et utilisez correctement cet équipement conformément à son Manuel d’Utilisation et aux réglementations nationales, gouvernementales et locales. Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux. Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre. En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions. Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes. Vérifier fréquemment le cordon d’alimentation et le conducteur de mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −, le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort. Mettre l’appareil hors tension quand on ne l’utilise pas. Ne pas utiliser des câbles usés, endommagés, sous dimensionnés ou réparés. Ne pas enrouler les câbles autour du corps. Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour. Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine. Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée. N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ les pièces endommagées. Entretenir l’appareil conformément à ce manuel. Porter un harnais de sécurité quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots. Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure. Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. Débrancher le câble pour le procédé non utilisé. OM-262 506 Page 7 Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire. Ne pas tester ni réarmer les prises femelles avec différentiel au régime de ralenti/en basse tension: cela endommagerait le disjoncteur différentiel, qui ne remplirait plus son rôle de protection contre une électrocution causée par un défaut de masse. Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS le moteur coupé. Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants. LES PIÈCES CHAUDES peuvent provoquer des brûlures. Ne pas toucher à mains nues les parties chaudes. Prévoir une période de refroidissement avant de travailler à l’équipement. Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux. Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier. Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. LES FUMÉES ET LES GAZ peuvent être dangereux. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé. Eloigner votre tête des fumées. Ne pas respirer les fumées. À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Pour déterminer la bonne ventilation, il est recommandé de procéder à un prélèvement pour la composition et la quantité de fumées et de gaz auxquels est exposé le personnel. Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé. Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux. Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger. Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants. Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. OM-262 506 Page 8 LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz comprimé en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). Porter des lunettes de sécurité avec écrans latéraux même sous votre casque. Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc. Porter un équipement de protection pour le corps fait d’un matériau résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette. LE SOUDAGE peut provoquer un incendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués. Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables. Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud. Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté. Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu ils n aient été préparés correctement conformément à AWS F4.1 et AWS A6.0 (voir les Normes de Sécurité). Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple). Brancher le câble de masse sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie. Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact. Porter un équipement de protection pour le corps fait d’un matériau résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette. Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes. Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes. Utiliser exclusivement des fusibles ou coupe−circuits appropriés. Ne pas augmenter leur puissance; ne pas les ponter. Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut affecter l’ouïe. Porter des protections approuvés pour les oreilles si le niveau sonore est trop élevé. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance. Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction. Si des BOUTEILLES sont endommagées, elles pourront exploser. Des bouteilles de gaz comprimé protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution. Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser. Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. Ne jamais placer une torche de soudage sur une bouteille à gaz. Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. Ne jamais souder une bouteille pressurisée − risque d’explosion. Utiliser seulement des bouteilles de gaz comprimé, régulateurs, tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état. Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors de l’ouverture de la vanne. Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille. Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles. Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales normes de sécurité. 2-3. Dangers existant en relation avec le moteur L’EXPLOSION DE LA BATTERIE peut provoquer des blessures. Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher des câbles de batterie, des câbles de chargeur de batterie (le cas échéant) ou de batterie d’entretien. Eviter de provoquer des étincelles avec les outils en travaillant sur la batterie. Ne pas utiliser l’appareil de soudage pour charger des batteries ou faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si l’appareil dispose d’une fonctionnalité de charge de batterie destinée à cet usage. Observer la polarité correcte (+ et −) sur les batteries. Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier lieu. Les sources d’étincelles, flammes nues, cigarettes et autres sources d’inflammation doivent être maintenues à l’écart des batteries. Ces dernières produisent des gaz explosifs en fonctionnement normal et en cours de charge. Respecter les consignes du fabricant de la batterie pour travailler sur une batterie ou à proximité. LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion. Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein. Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue. Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son expansion. Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renversé avant de faire démarrer le moteur. Jeter les chiffons dans un récipient ignifuge. Toujours garder le pistolet en contact avec le réservoir lors du remplissage. Les PIÈCES MOBILES peuvent causer des blessures. S’abstenir de toucher des parties mobiles telles que des ventilateurs, courroies et rotors. Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection. Arrêter le moteur avant d’installer ou brancher l’appareil. Lorsque cela est nécessaire pour des travaux d entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié. OM-262 506 Page 9 Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, débrancher le câble négatif (−) de batterie de la borne. Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes mobiles. Remettre en place les portes, panneaux, recouvrements ou dispositifs de protection à la fin des travaux d’entretien et avant de mettre le moteur en marche. Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en route accidentelle du moteur. Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le générateur. LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie. Empêcher les étincelles d’échappement du moteur de provoquer un incendie. Utiliser uniquement un pare-étincelles approuvé − voir codes en vigueur. LES PIÈCES CHAUDES peuvent provoquer des brûlures. Ne pas toucher des parties chaudes à mains nues. Prévoir une période de refroidissement avant de travailler à l’équipement. Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des brûlures. Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter de se brûler. Toujours vérifier le niveau de liquide de refroidissement dans le vase d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du moteur). Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. L’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. Les fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisible et inodore. JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes. Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et bouches aération. L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et sur la PEAU. Ne pas renverser la batterie. Remplacer une batterie endommagée. Rincer immédiatement les yeux et la peau à l’eau. LA CHALEUR DU MOTEUR peut provoquer un incendie. Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. Tenir à distance les produits inflammables de l’échappement. 2-4. Dangers liés à l’air comprimé Un ÉQUIPEMENT PNEUMATIQUE risque de provoquer des blessures ou même la mort. Une installation ou une utilisation incorrecte de cet appareil pourrait conduire à des dégâts matériels ou corporels. Seul un personnel qualifié est autorisé à installer, utiliser et entretenir cet appareil conformément à son manuel d’utilisation, aux normes industrielles et aux codes nationaux, d’état ou locaux. Ne pas dépasser le débit nominal ou la capacité du compresseur ou de tout équipement du circuit d’air comprimé. Concevoir le circuit d’air comprimé de telle sorte que la défaillance d’un composant ne risque pas de provoquer un accident matériel ou corporel. Avant d’intervenir sur le circuit d’air comprimé, couper l’alimentation électrique, verrouiller et étiqueter l’appareil, détendre la pression et s’assurer que le circuit d’air ne peut être mis sous pression par inadvertance. Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil fonctionne. Seul un personnel qualifié est autorisé, et appliquant les consignes du fabricant. Ne pas modifier ou altérer le compresseur ou les équipements fournis par le fabricant. Ne pas débrancher, désactiver ou neutraliser les équipements de sécurité du circuit d’air comprimé. Utiliser uniquement des composants et accessoires homologués par le fabricant. Se tenir à l’écart de tout point présentant un danger de pincement ou d’écrasement créé par l’équipement raccordé au circuit d’air comprimé. OM-262 506 Page 10 Ne pas intervenir sous ou autour d’un équipement qui n’est soutenu que par la pression pneumatique. Soutenir l’équipement de façon appropriée par un moyen mécanique. MÉTAL CHAUD provenant du découpage ou du gougeage à l’arc risque de provoquer un incendie ou une explosion. Ne pas découper ou gouger à proximité de produits inflammables. Attention aux risques d’incendie: tenir un extincteur à proximité. L’AIR COMPRIMÉ risque de provoquer des blessures ou même la mort. Avant d’intervenir sur le circuit d’air comprimé, couper l’alimentation électrique, verrouiller et étiqueter l’appareil, détendre la pression et s’assurer que le circuit d’air ne peut être mis sous pression par inadvertance. Détendre la pression avant de débrancher ou de brancher des canalisations d’air. Avant d’utiliser l’appareil, contrôler les composants du circuit d’air comprimé, les branchements et les flexibles en recherchant tout signe de détérioration, de fuite et d’usure. Ne pas diriger un jet d’air vers soi−même ou vers autrui. Pour intervenir sur un circuit d’air comprimé, porter un équipement de protection tel que des lunettes de sécurité, des gants de cuir, une chemise et un pantalon en tissu résistant, des chaussures montantes et une coiffe. Pour rechercher des fuites, utiliser de l’eau savonneuse ou un détecteur à ultrasons, jamais les mains nues. En cas de détection de fuite, ne pas utiliser l’équipement. Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de mettre en marche l’appareil. En cas d’injection d’air dans la peau ou le corps, demander immédiatement une assistance médicale. L’INHALATION D’AIR COMPRIMÉ risque de provoquer des blessures ou même la mort. Ne pas inhaler d’air comprimé. Utiliser l’air comprimé uniquement pour découper ou gouger ainsi que pour l’outillage pneumatique. Une PRESSION D’AIR RÉSIDUELLE ET DES FLEXIBLES QUI FOUETTENT risquent de provoquer des blessures. Détendre la pression pneumatique des outils et circuits avant d’entretenir, ajouter ou changer des accessoires et avant d’ouvrir le bouchon de vidange ou de remplissage d’huile du compresseur. Les PIÈCES MOBILES peuvent causer des blessures. S’abstenir de toucher des parties mobiles telles que des ventilateurs, courroies et rotors. Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection. Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes mobiles. Avant d’intervenir sur le circuit d’air comprimé, couper l’alimentation électrique, verrouiller et étiqueter l’appareil, détendre la pression et s’assurer que le circuit d’air ne peut être mis sous pression par inadvertance. Demander seulement à un personnel qualifié d’enlever les dispositifs de sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de dépannage. Remettre en place les portes, panneaux, recouvrements ou dispositifs de protection à la fin des travaux d’entretien et avant de mettre le moteur en marche. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. Ne pas toucher de pièces chaudes du compresseur ou du circuit d’air. Prévoir une période de refroidissement avant d’intervenir sur l’équipement. Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. LIRE LES INSTRUCTIONS. Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. N’utiliser que les pièces de rechange recommandées par le constructeur. Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux. 2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. Ne pas installer l’appareil à proximité de produits inflammables. Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service. LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures. Utiliser l’anneau de levage pour lever l’appareil et les accessoires correctement installées seuls, PAS les bouteilles de gaz. Ne pas dépasser le poids nominal maximal de l’œilleton (voir les spécifications). Utiliser un équipement de levage de capacité suffisante pour lever l’appareil. En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. Tenir l’équipement (câbles et cordons) à distance des véhicules mobiles lors de toute opération en hauteur. Suivre les consignes du Manuel des applications pour l’équation de levage NIOSH révisée (Publication Nº94−110) lors du levage manuelle de pièces ou équipements lourds. LE SURCHAUFFEMENT peut endommager le moteur électrique. Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur. Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles. Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a lieu. LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures. Porter un écran facial pour protéger le visage et les yeux. Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps. Les étincelles risquent de causer un incendie − éloigner toute substance inflammable. Les PIÈCES MOBILES peuvent causer des blessures. Ne pas s’approcher des organes mobiles. Ne pas s’approcher des points de coincement tels que des rouleaux de commande. OM-262 506 Page 11 LA SORTIE DE RECHARGE et L’EXPLOSION DE LA BATTERIE peuvent provoquer des blessures. La recharge de batterie n’existe pas sur tous les modèles. Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher des câbles de batterie, des câbles de chargeur de batterie (le cas échéant) ou de batterie d’entretien. Eviter de provoquer des étincelles avec les outils en travaillant sur la batterie. Ne pas utiliser l’appareil de soudage pour charger des batteries ou faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si l’appareil dispose d’une fonctionnalité de charge de batterie destinée à cet usage. Observer la polarité correcte (+ et −) sur les batteries. Débrancher le câble négatif (−) en premier lieu. Le rebrancher en dernier lieu. Les sources d’étincelles, flammes nues, cigarettes et autres sources d’inflammation doivent être maintenues à l’écart des batteries. Ces dernières produisent des gaz explosifs en fonctionnement normal et en cours de charge. Respecter les consignes du fabricant de la batterie pour travailler sur une batterie ou à proximité. Les opérations de charge de batterie ne doivent être effectuées que par des personnes qualifiées. Pour enlever la batterie d’un véhicule pour la recharge, débrancher tout d’abord le câble négatif (−) et le rebrancher en dernier lieu. Pour éviter un arc, s’assurer que tous les accessoires sont débranchés. Ne charger que des batteries plomb−acide. Ne pas utiliser le chargeur de batterie pour alimenter un autre circuit électrique basse tension ou pour charger des batteries sèches. Ne pas charger une batterie gelée. Ne pas utiliser de câbles de charge endommagés. Ne pas charger des batteries dans un espace fermé ou en l’absence d’une ventilation. Ne pas charger une batterie dont les bornes sont desserrées ou présentant une détérioration comme par exemple un boîtier ou un couvercle fissuré. Avant de charger une batterie, sélectionner la tension de charge correspondant à la tension de la batterie. Régler les commandes de charge de batterie sur la position d’arrêt avant de brancher la batterie. Veiller à ce que les pinces de charge ne se touchent pas. LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes. UNE REMORQUE QUI BASCULE peut provoquer des blessures. Utiliser les supports de la remorque ou des blocs pour soutenir le poids. Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant. LIRE LES INSTRUCTIONS. Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. N’utiliser que les pièces de rechange recommandées par le constructeur. Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs. Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation. L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. Si le FCC signale des interférences, arrêter immédiatement l’appareil. Effectuer régulièrement le contrôle et l’entretien de l’installation. Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles. Ranger les câbles de charge à distance du capot, des portes et des pièces mobiles du véhicule. LE SOUDAGE À L’ARC risque de provoquer des interférences. LES FILS DE SOUDAGE peuvent provoquer des blessures. Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage. L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT. Laisser l’équipement refroidir ; respecter le facteur de marche nominal. Réduire le courant ou le facteur de marche avant de poursuivre le soudage. Ne pas obstruer les passages d’air du poste. OM-262 506 Page 12 L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots. Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement. Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi. En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail. 2-6. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants) Les batteries, les bornes et autres accessoires contiennent du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Se laver les mains après manipulation. Pour les moteurs à essence : Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Pour les moteurs diesel : Les gaz d’échappement des moteurs diesel et certains de leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations congénitales ou autres problèmes de procréation. Ce produit contient des produits chimiques, notamment du plomb, dont l’État de Californie reconnaît qu’ils provoquent des cancers, des malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après utilisation. 2-7. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org). Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.) OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814 (phone: 301-504-7923, website: www.cpsc.gov/cpscpub/pubs/portgen.pdf). Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH). 2-8. Informations relatives aux CEM Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques (CEM) à certains endroits. Le courant issu d’un soudage à l’arc (et de procédés connexes, y compris le soudage par points, le gougeage, le découpage plasma et les opérations de chauffage par induction) crée un champ électromagnétique (CEM) autour du circuit de soudage. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises: par exemple, des restrictions d’accès pour les passants ou une évaluation individuelle des risques pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM provenant du circuit de soudage: 1. Rassembler les câbles en les torsadant ou en les attachant avec du ruban adhésif ou avec une housse. 2. Ne pas se tenir au milieu des câbles de soudage. Disposer les câbles d’un côté et à distance de l’opérateur. 3. Ne pas courber et ne pas entourer les câbles autour de votre corps. 4. Maintenir la tête et le torse aussi loin que possible du matériel du circuit de soudage. 5. Connecter la pince sur la pièce aussi près que possible de la soudure. 6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir ou se pencher dessus. 7. Ne pas souder tout en portant la source de soudage ou le dévidoir. En ce qui concerne les implants médicaux : Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes. OM-262 506 Page 13 Complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012−05 Protect yourself from electric shock by insulating yourself from work and ground. Safe3 2012−05 Keep your head out of the fumes. Safe6 2012−05 Use forced ventilation or local exhaust to remove the fumes. Safe8 2012−05 Use ventilating fan to remove fumes. Safe10 2012−05 Keep flammables away from welding. Do not weld near flammables. Safe12 2012−05 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Safe14 2012−05 Do not weld on drums or any closed containers. Safe16 2012−05 Do not remove or paint over (cover) the label. Safe20 2012−05 OM-262 506 Page 14 Complete Parts List is available at www.MillerWelds.com Do not work on unit if engine is running. Stop engine first. Safe21 2012−05 Do not smoke while fueling or if near fuel. Safe22 2012−05 Stop engine before fueling. Safe23 2012−05 Do not fuel a hot engine. Safe24 2012−05 Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye rating (see Specifications). Safe25 2012−05 Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual. Safe89 2015−02 Hot muffler and exhaust pipe can cause severe burns. Safe90 2012−07 Welding, cutting, drilling, or grinding on base can cause fire or explosion. Safe91 2012−07 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility. Contact your local recycling office or your local distributor for further information. Safe37 2012−05 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. Safe38 2012−05 Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Become trained and read the instructions before working on the machine or welding. Safe40 2012−05 OM-262 506 Page 15 Complete Parts List is available at www.MillerWelds.com Engine fuel plus flames or sparks can cause fire. = Safe45 2012−05 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. Safe46 2012−05 Read Owner’s Manual. Read labels on unit. Safe47 2012−05 Read Owner’s Manual. Follow instructions to activate battery. Safe48 2012−05 0 - 50 h std During the first 50 hours of operation keep welding load above 200 amperes. Do not weld below 200 amperes of output. Safe54 2012−05 50 h std After the first 50 hours of operation, change the engine oil and filter. Safe55 2012−05 Never use generator inside a home or garage, even if doors and windows are open. Safe87 2012−07 Only use generator outside and far away from windows, doors, and vents. Safe88 2012−07 3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. A V S Amperage Voltage Suitable For Welding In An Environment With Increased Risk Of Electric Shock Direct Current (DC) OM-262 506 Page 16 X I2 U2 U0 Duty Cycle Rated Welding Current Conventional Load Voltage Rated No−Load Voltage (OCV) I n n0 Current Rated Load Speed Rated No−Load Speed Complete Parts List is available at www.MillerWelds.com n1 P1max Hz h Rated Idle Speed Output Engine RPM Maximum Power Consumption Off Engine Stop Hertz On Engine Oil Hours Seconds Clock, Time Switch Hour Meter Increase or Decrease of Quantity (Rotating) Fuel Filter Do Not Switch While Welding Engine Coolant Remote Engine Coolant Temperature Read Operator’s Manual Engine Temperature Sound Level Welding (General) Alternating Current (AC) Single Phase Three Phase Engine−Driven 3−Phase Alternator with Rectifier Battery (Engine) Shielded Metal Arc Welding (SMAW) Engine Belt Gas Metal Arc Welding (GMAW) Manual Cleaning Gas Tungsten Arc Welding (GTAW) / Tungsten Inert Gas (TIG) Welding Spark Arrestor Contractor On Tungsten Inert Gas (TIG) Lift Arc Air Filter Arc Force (DIG) Starting Aid (Preheat) Air Cleaner Work Connection Engine Check Air Cleaner Negative Engine Check Injectors/Pump Positive Engine Check Valve Clearance Protective Earth (Ground) Slow Certified/Trained Mechanic Circuit Breaker Supplementary Protector Fast iso 7000 Call for Maintenance OM-262 506 Page 17 Complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2. Weld, Power, And Engine Specifications Generator Power Rating Engine CAT Turbo C1.5T Water−Cooled Three−Cylinder 24 HP Diesel Engine Welding Mode Single-Phase, 10 kVA/kW, 83/42 A, 120/240 V AC, 60 Hz Mitsubishi Water−Cooled Four−Cylinder 24.4 HP Diesel Engine CC/DC CV/DC Weld Output Range Rated Welding Output Maximum Open-Circuit Voltage Fuel Capacity 20 − 400 A 14 − 40 V 400 A, 24 Volts DC, 100% Duty Cycle 350 A, 27 Volts DC 100% Duty Cycle 300 A, 32 Volts DC 100% Duty Cycle 85* 11.5 gal (43.5 L) * With Low OCV switch (Voltage Reducing Device, VRD) enabled, open−circuit voltage is 13 to 15 volts DC until arc initiation. 4-3. Dimensions, Weights, And Operating Angles Dimensions 32 in. (813 mm) 35-3/4 in. (908 mm) (to top of lift eye) Height Width G 26-1/4 in. (667 mm) (mtg. brackets turned in) 28-3/4 in. (730 mm) (mtg. brackets turned out) Depth 56 in. (1422 mm) A 56 in. (1422 mm) B 54 in. (1372 mm) C 52 in in. (1321 mm) D 2 in. (51 mm) E 26 in. (660 mm) F 7/8 in. (22 mm) G 27-3/4 in. (705 mm) H 9/16 in. (14 mm) Dia. 4 Holes Weight No fuel: 1018 lb (462 kg) A B ! Do not exceed tilt angles or engine could be damaged or unit could tip. ! Do not move or operate unit where it could tip. C 30° H Front Panel End D 20° F 30° 20° E 907 428−1 w/ fuel: 1100 lb (499 kg) Lifting Eye Weight Rating: 2000 lb (907 kg) Maximum 4-4. Environmental Specifications A. IP Rating IP Rating IP23S This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless sheltered. OM-262 506 Page 18 Operating Temperature Range −40 to 104°F (−40 to +40°C) IP23S 2014−06 Complete Parts List is available at www.MillerWelds.com B. Information On Electromagnetic Fields (EMF) ! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person. Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure information. The EMF assessment on this equipment was conducted at 0.5 meter. At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values. ce-emf 1 2010-10 C. Information On Electromagnetic Compatibility (EMC) ! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low− voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conce-emc 3 2011-09 ducted as well as radiated disturbances. 4-5. Duty Cycle And Overheating 1 1 100% Duty Cycle Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. This unit is rated for welding at 325 amperes continuously. For best performance when welding above 300 amperes, place Engine Control switch in Run position. NOTICE − Exceeding duty cycle can damage unit and void warranty. Weld Amperes 400 300 200 0 10 20 30 40 50 60 70 80 90 100 % Duty Cycle 248 003−A OM-262 506 Page 19 Complete Parts List is available at www.MillerWelds.com 4-6. Volt-Ampere Curves For Models With CAT Engine A. Stick Mode The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welder/generator. Curves of all other settings fall between the curves shown. 100 For DC Volts 80 best performance when welding above 300 amperes, place Engine Control switch in Run position. 60 40 20 0 0 100 200 300 400 DC Amperes B. TIG Mode 100 80 DC Volts 60 40 20 0 0 100 200 300 400 DC Amperes C. MIG Mode DC Volts 60 40 20 0 0 OM-262 506 Page 20 100 200 DC Amperes 300 400 247 987-A / 247 988-A Complete Parts List is available at www.MillerWelds.com 4-7. Volt-Ampere Curves For Models With Mitsubishi Engine A. Stick Mode The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welder/generator. Curves of all other settings fall between the curves shown. 100 90 80 70 DC Volts 60 50 40 Max Min 30 20 10 0 0 100 200 300 DC Amperes 400 500 B. MIG Mode 100 90 80 70 DC Volts 60 50 Max 40 30 20 Min 10 0 0 100 200 DC Amperes 300 400 C. TIG Mode 100 90 80 70 DC Volts 60 50 40 Max 30 Min 20 10 0 0 100 200 300 DC Amperes 400 500 250 372-A / 250 371−A / 250 373-A OM-262 506 Page 21 Complete Parts List is available at www.MillerWelds.com 4-8. CAT Engine Fuel Consumption The curve shows typical fuel use under weld or power loads. 2.00 1.75 US Gal./Hr. 1.50 1.25 1.00 0.75 0.50 IDLE 0.25 0.00 0 50 100 150 200 250 300 350 400 DC Weld Amperes At 100% Duty Cycle 247 984-A 4-9. Mitsubishi Engine Fuel Consumption The curve shows typical fuel use under weld or power loads. 2.00 1.75 1.50 U.S. GAL/HR. 1.25 1.00 0.75 0.50 IDLE 0.25 0.00 0 50 100 150 200 250 300 350 400 DC WELD AMPERES AT 100% DUTY CYCLE 250 370-A OM-262 506 Page 22 Complete Parts List is available at www.MillerWelds.com 4-10. AC Generator Power Curve The AC power curve shows the generator power in amperes. 280 270 AC Volts 260 250 240 230 220 210 200 190 180 0 10 20 30 AC Amperes 40 50 60 247 989-A Notes OM-262 506 Page 23 Complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Installing Welder/Generator Airflow Clearance 18 in. (460 mm) Movement 18 in. (460 mm) 18 in. (460 mm) OR OR 18 in. (460 mm) 18 in. (460 mm) Location/Mounting 2 Welding Unit In Place Bolting Unit In 2 Place 3 4 OR OR Tools Needed: 1 1 9/16 in. Go to MillerWelds.com for more information on truck installations. Movement ! Do not move or operate unit where it could tip. See Section 4-3 for lifting eye rating. Airflow Clearance NOTICE − Do not install unit where air flow is restricted or engine may overheat. Location/Mounting ! Always securely fasten welder/generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. OM-262 506 Page 24 install3 2014−12 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 ! Do not weld on base. Welding on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. NOTICE − Do not mount unit by supporting the base only at the four mounting brackets. Use cross-supports to adequately support unit and prevent damage to base. 1 Cross-Supports 2 Mounting Brackets (Supplied) Mount unit on flat surface or use cross-supports to support base. Secure unit with mounting brackets. 3 1/2 in Bolt And Washer (Minimum − Not Supplied) 4 3/8-16 x 1 in. Screws (Supplied) To Bolt Unit In Place: Remove hardware securing the four mounting brackets to the base. Reverse brackets and reattach to base with original hardware. Mount unit to truck or trailer with 1/2 in. (12 mm) or larger hardware (not supplied). To Weld Unit In Place: Weld unit to truck or trailer only at the four mounting brackets. Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator To Truck Or Trailer Frame 1 2 GND/PE 3 rot_grnd2 2014−11 − 800 652-D ! Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. ! Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators. ! Bed liners, shipping skids, and some running gear insulate the welder/generator from the vehicle ! frame. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown. 1 Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Connect cable from equipment ground terminal to metal vehicle frame. Use #8 AWG or larger insulated copper wire. 2 3 Equipment Grounding Terminal (On Front Panel) Grounding Cable (Not Supplied) Metal Vehicle Frame Electrically bond generator frame to vehicle frame by metal-to-metal contact. 5-3. Installing Exhaust Pipe ! Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Tools Needed: 1/2 in. Exhaust Pipe3 2010−04 / Ref 803 582 OM-262 506 Page 25 Complete Parts List is available at www.MillerWelds.com 5-4. Connecting The Battery − Tools Needed: 1/2 in. + Shown with door open and rocker panel removed. Conn_Batt2 2014−06 / S-0756-C / 161-002 NOTICE − Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and before being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open−circuit voltage drops to 12.4 volts DC when measured across the battery terminals. ! Connect negative (−) cable last. Notes OM-262 506 Page 26 NOTICE − Wait two minutes after engine shutdown before disconnecting battery or engine controller may be damaged. Battery is accessed through the side door. Connect battery, negative cable last. Close side door. Do not allow the battery cables to touch opposing terminals. When connecting the battery cables attach the positive (+) cable to the positive (+) battery terminal first, followed by negative (−) cable to negative (−) battery terminal. Never start the engine when the cables are loose or poorly connected to the battery terminals. Never disconnect the battery while the engine is running. Never use a quick battery charger to start the engine. Do not charge battery with Engine Control switch On. Always disconnect the negative (−) battery cable before charging battery. Complete Parts List is available at www.MillerWelds.com 5-5. Engine General Information Check all engine fluids daily. Engine must be cold and on a level surface. Automatic Shutdown System Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high. This unit has a low oil pressure shut- down switch. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the oil pres- sure shutdown system to monitor oil level. Run-In NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods of time may cause wetstacking or engine damage. Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe during run-in, see Section 11. Cold Weather To improve cold weather starting: Use Preheat switch (see Section 6-2). Keep battery in good condition. Store battery in warm area. Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for fuel information. Use correct grade oil for cold weather (see engine manual). Use engine block heater if applicable (see Section 6-10). Gen_engine1 2012−04 5-6. Engine Fuel And Coolant Prestart Information Check radiator coolant level when fluid is low in recovery tank. Full Full Diesel Engine stops if fuel level is low. Coolant Recovery Tank Hot Full Capacity: 6 qt (5.7 L) Cold Full Fuel/Coolant_engine1 2012−04 Ref: 907 427−6−2 Fuel NOTICE − Do not use gasoline. Gasoline will damage engine. Add fresh diesel fuel before starting (see engine maintenance label for fuel specifications). Leave filler neck empty to allow room for expansion. Coolant Check coolant level in radiator before start- ing unit the first time. If necessary, add coolant to radiator until coolant level is at bottom of filler neck. Check coolant level in recovery tank daily. If necessary, add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels. If recovery tank coolant level was low, also check coolant level in radiator. Add coolant if level is below bottom of radiator filler neck. Unit is shipped with an engine coolant mixture of water and ethylene glycol base antifreeze rated to −34° F (−37° C). Add antifreeze to mixture if using the unit in temperatures below −34° F (−37° C). Keep radiator and air intake clean and free of dirt. NOTICE − Incorrect engine temperature can damage engine. Do not run engine without a properly working thermostat and radiator cap. OM-262 506 Page 27 Complete Parts List is available at www.MillerWelds.com 5-7. CAT Engine Oil Prestart Information Check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label). Full 907 427-6 5-8. Mitsubishi Engine Oil Prestart Information Check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label). Full 907 427-6 OM-262 506 Page 28 Complete Parts List is available at www.MillerWelds.com 5-9. Weld Output Terminals 1 2 256 735-A 1 Negative (−) Weld Output Terminal 2 Positive (+) Weld Output Terminal For Direct Current Electrode Negative (DCEN), reverse cable connections. TIG (GTAW) Welding For TIG welding Direct Current Electrode Negative (DCEN), connect torch to Negative (−) terminal and work cable to Positive (+) terminal. MIG And FCAW Welding For MIG and FCAW welding Direct Current Electrode Positive (DCEP), connect wire Use Process switch to select type of weld output (see Section 6-2). Stick Welding For Stick welding Direct Current Electrode Positive (DCEP), connect electrode holder cable to Positive (+) terminal and work cable to Negative (−) terminal. 5-10. feeder cable to Positive (+) terminal and work cable to Negative (−) terminal. For Direct Current Electrode Negative (DCEN), reverse cable connections. CAC-A Gouging For CAC-A connect electrode holder cable to Positive (+) terminal and work cable to Negative (−) terminal. Connecting To Weld Output Terminals ! Stop engine. ! Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. Do not place anything between weld cable terminal and copper bar. Make sure that the surfaces of the weld cable terminal and copper bar are clean. Tools Needed: 3/4 in. 1 1 6 3 2 Correct Weld Cable Connection 2 Incorrect Weld Cable Connection 3 4 5 6 Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar. 4 5 803 778-B OM-262 506 Page 29 Complete Parts List is available at www.MillerWelds.com 5-11. Selecting Weld Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size. Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less ! * This 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft 400 ft (105 m) (120 m) Welding Amperes 10 − 60% Duty Cycle 60 − 100% Duty Cycle 100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60) 150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95) 200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120) Stop engine before connecting to weld output terminals. 250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 2/0 (2x70) Do not use worn, damaged, undersized, or repaired cables. 300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 2 ea. 4/0 (2x120) 500 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 3/0 (3x95) Weld Output Terminals ! 150 ft (45 m) 10 − 100% Duty Cycle chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable. **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-K 2013−09 5-12. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information Not all models have contactor control. See description of front panel controls and circuit diagram. A 24 volts AC. Protected by supplementary protector. B Contact closure to A completes 24 volt AC contactor control circuit. C Output to remote control:+10 volts DC in MIG mode; 0 to +10 volts DC in Stick or TIG mode. D Remote control circuit common. E DC input command signal: 0 to +10 volts from min. to max. of remote control with Voltage/Amperage Adjust control at maximum. F Current feedback: 1 volt per 100 amperes. H Voltage feedback: 1 volt per 10 arc volts. GND K Chassis common. NEUTRAL G Circuit common for 24 and 115 volt AC circuit. 24 VOLTS AC *The remaining sockets are not used. Accessories depend REMOTE OUTPUT CONTROL on unit capabilities. OR Rmt14_1 2010−04 OM-262 506 Page 30 Complete Parts List is available at www.MillerWelds.com Notes OM-262 506 Page 31 Complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATING WELDER/GENERATOR 6-1. Front Panel Controls (See Section 6-2) 6 8 7 9 10 5 11 1 2 3 4 North American Auxiliary Power Panel Shown. 256 735-A / 907 428−1 OM-262 506 Page 32 Complete Parts List is available at www.MillerWelds.com 6-2. Description Of Front Panel Controls (See Section 6-1) Engine Starting Controls 1 Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions following). 2 Engine Control Switch Use switch to start engine, select engine speed, and stop engine. In Run position, engine runs at weld/power speed. In Run/Idle position, engine runs at idle speed at no load and weld speed with load applied. For best performance when welding above 300 amperes, place Engine Control switch in Run position. NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods of time may cause wetstacking or engine damage. To Start: NOTICE − Do not use ether or other starting fluids. Using starting fluids voids warranty. If engine does not start, let engine come to a complete stop before attempting restart. Above 325 F (05 C): turn Engine Control switch to Start. Release Engine Control switch when engine starts. Below 325 F (05 C): turn engine control switch to Run position. Push Preheat switch up for 6 seconds. Turn Engine Control switch to Start. Release Engine Control switch and Preheat switch when engine starts. Do not operate Preheat switch for more than 20 seconds at a time. To Stop: turn Engine Control switch to Off position. Engine Gauges, Meters, And Lights See Section 6-9 for complete fuel/hour gauge information. 3 Fuel/Hour Gauge Use gauge to check fuel level, total engine operating hours, or hours to oil change. To check fuel level or engine hours when engine is not running, turn Engine Control switch to Run/Idle position. 4 Engine Indicator Light Light goes on and engine stops if fuel is low, engine temperature exceeds 230° F (110° C) or engine oil pressure is below 10 psi (69 kPa). Normal engine temperature is 180 - 203 F (82 - 95 C). Normal oil pressure is 30 - 60 psi (207 - 414 kPa). NOTICE − Do not run engine until trouble is fixed. 5 Engine Coolant Temperature Gauge Normal temperature is 180 - 203° F (82 - 95° C). Engine stops if temperature exceeds 230° F (110° C). Weld Controls 6 Remote Control Receptacle Use receptacle to connect remote controls, wire feeders, and tools requiring 24 VAC. When a remote control is connected to the Remote receptacle, the Auto Sense Remote feature automatically switches voltage/amperage control to the remote control (see Section 6-8). With remote control connected, weld output is determined by a combination of front panel and remote control voltage/amperage settings. If no remote control is connected to the Remote receptacle, the front panel Voltage/Amperage control adjusts voltage and amperage. If a remote device connected to Remote Receptacle RC14 is faulty or is disconnected during operation, the meters display Help 25 (see Section 8-11). Clear fault by stopping and restarting the unit or by turning Process/Contactor switch to another position. 7 Process/Contactor Switch See Section 6-3 for Process/Contactor switch information. 8 Arc Control See Section 6-4 for Arc Control information. 9 Voltage/Amperage Control With Process/Contactor switch in any Stick or TIG setting, use control to adjust amperage. With Process/Contactor switch in any Wire (MIG) position, use control to adjust voltage. Control limits the remote amperage in Stick or TIG mode, but has no effect in Wire (MIG) modes. Weld Meters Weld meters also work in combination to display troubleshooting help codes (see Section 8-11). 10 DC Voltmeter Voltmeter displays preset voltage (MIG welding) with contactor off, and actual output voltage with the contactor on. Voltmeter displays voltage at the weld output terminals, but not necessarily the welding arc due to resistance of cable and connections. To set voltage, turn Process/Contactor switch to MIG or FCAW position. Turn V/A control until desired voltage is displayed on Voltmeter. When welding is finished, voltmeter displays weld voltage and then defaults to preset voltage. 11 DC Ammeter Ammeter displays preset amperage (Stick and TIG only) when not welding, and actual output amperage when welding. To set amperage, turn Process/Contactor switch to Stick or TIG position. Turn V/A control until desired amperage is displayed on Ammeter. When welding is finished, ammeter displays weld amperage and then defaults to preset amperage. OM-262 506 Page 33 Complete Parts List is available at www.MillerWelds.com 6-3. Process/Contactor Switch 1 1 Process/Contactor Switch ! Weld output terminals are energized when Process/Contactor switch is in an Electrode Hot position and the engine is running. Use switch to select weld process and weld output on/off control (see table below). Place switch in Remote On/Off Switch Required positions to turn weld output on and off with a device connected to the Remote 14 receptacle. Place switch in Electrode Hot positions for weld output to be on whenever the engine is running. Use Stick mode for air carbon arc (CAC-A) cutting and gouging. Use the Lift-Arc TIG mode for TIG (GTAW) welding using the Lift-Arc TIG starting procedure (see Section 6-7). Ref. 246 345-B / Ref. 907 428−1 REMOTE ON/OFF REQUIRED ELECTRODE HOT Switch Setting Typical Process Applications (DC Only) Electrode Hot – MIG VS MIG solid wire uses a voltage sensing (VS) feeder that does not require a control cable back to the welder/generator. Electrode Hot – FCAW VS FCAW (Flux Cored Arc Welding) uses a voltage sensing (VS) feeder that does not require a control cable back to the welder/generator. Electrode Hot - Stick Stick welding with or without a remote amperage control. Strike an arc to start welding. Electrode Hot – TIG Lift Arc Lift Arc TIG: touch tungsten to work and lift to start welding. Uses circuitry internal to the welder/generator to aid arc start. Can be used with or without a remote control. Remote ON/OFF Required - TIG High Frequency TIG or Scratch Start TIG welding. High frequency TIG starting with remote foot control allows remote On/Off and Amperage control. Another typical application is a simple TIG rig with a remote control device. Remote On/Off Required - Stick Stick welding with RFC-14 control allows remote On/Off and Amperage control. This can help eliminate accidental arc strikes. Remote On/Off Required - FCAW FCAW using a constant speed feeder. Use feeders with remote voltage control, or use a Spoolmatic 30A with WC 24 control. Remote On/Off Required - MIG MIG solid wire using a constant speed feeder. Use feeders with remote voltage control, or use a Spoolmatic 30A with WC 24 control. OM-262 506 Page 34 Complete Parts List is available at www.MillerWelds.com 6-4. Arc Control 1 Arc Control Stick Control adjusts Dig when Stick is selected on mode switch. 1 When control is set toward minimum, short-circuit amperage at low arc voltage is the same as normal welding amperage. When set toward maximum, shortcircuit amperage is increased at low arc voltage to help prevent the electrode from sticking while welding (see volt-ampere curves in Sections 4-6 and 4-7). Select setting best suited for application. FCAW/MIG Control adjusts inductance when FCAW or MIG position is selected on the mode switch. Inductance determines the “wetness” of the weld puddle. Increasing Arc Control setting decreases inductance, thereby increasing puddle fluidity (“wetness”). Decreasing Arc Control setting increases inductance, decreasing puddle fluidity. TIG When the control is set below 1, Auto Stop is a variable function of pre-set weld amperage. This is used with a short arc length where flare at arc shutdown cannot be tolerated. When the control is set above 1, Auto Stop voltage threshold is a set value based on pre-set weld amperage (I) as follows: I <= 50 A, V=17 I >50 to <=100 A, V=22 I >100 to <=190 A, V=25 I >190A, V=30 This allows for a longer arc length (such as when “walking the cup”), where nuisance shutdowns are undesirable. Control is not functional when TIG Remote mode is selected. 257 145-A OM-262 506 Page 35 Complete Parts List is available at www.MillerWelds.com 6-5. Low Open-Circuit Voltage (VRD) Switch Mode 1 Voltage Reducing Device (VRD) Switch The VRD switch can be set for low open-circuit voltage operation in Stick mode. When the unit is configured for low open-circuit voltage operation only a low sensing voltage (approximately 15 volts DC) is present between the electrode and workpiece prior to the electrode touching the workpiece. 1 ON OFF 803 562 6-6. Stick Start Procedure − Scratch Start Technique With Stick selected, start arc as follows: 1 2 3 Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it. 1 2 3 OM-262 506 Page 36 Electrode Workpiece Arc VRD Switch On: Normal open-circuit voltage is not present before electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece. For optimal starting performance, a good clean contact must be made between the electrode and workpiece. Complete Parts List is available at www.MillerWelds.com 6-7. Lift-Arct TIG With Auto-Stopt Arc Start With Lift-Arc TIG Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted. Arc Start With Lift-Arc 1 Select Lift-Arc TIG at Process/ Contactor switch. 2 Turn gas on. 1 2 Touch or scratch. Lift at any angle. Touch tungsten electrode to workpiece at weld start point. Slowly lift electrode. Arc is started when electrode is lifted. Maintain shielding gas coverage and eliminate tungsten and workpiece contamination by using Auto-Stop to end the arc. Arc End With Auto-Stop 1 2 3 Arc End With Auto-Stop: 1 2 3 While welding. Lift torch to start Auto-Stop. Arc stops. Move torch back down to maintain gas coverage and prevent contamination. WM Marketing Notes OM-262 506 Page 37 Complete Parts List is available at www.MillerWelds.com 6-8. Remote Voltage/Amperage Control 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-12). When a remote control is connected to the 1 2 Remote receptacle, the Auto Sense Remote feature automatically switches voltage/amperage control to the remote control. When a device is connected to the Remote receptacle, remote voltage/amperage control is always available regardless of the position of the Process/Contactor switch. 3 2 3 In Example: Min = 20 A DC Max = 205 A DC Voltmeter Shows Open-Circuit Voltage When Not Welding, Arc Voltage While Welding 56 Connect Remote Control To Remote Receptacle RC14 Set TIG or STICK Process Voltmeter Shows Preset Output When Not Welding, Actual Voltage While Welding 28 0 Voltmeter Ammeter 205 Turn Remote Control On. Adjust Optional Remote Control to 100% Ammeter Shows Preset Output When Not Welding, Actual Amperage While Welding Set V/A Control To Desired Maximum Weld Output Using Weld Meters Ammeter Shows Zero Max (205 A DC) Min (20 A DC) Adjust Optional Remote Control to desired weld output Weld meters show preset output when not welding. Adjust Optional Remote Control to desired weld output Connect Remote Control To Remote Receptacle RC14 Set WIRE Process 0774 / Ref.246 345-B / Ref. 907 428−1 OM-262 506 Page 38 Complete Parts List is available at www.MillerWelds.com 6-9. Fuel/Hour Gauge Descriptions OM-262 506 Page 39 Complete Parts List is available at www.MillerWelds.com 6-10. Operating Optional Engine Block Heater 1 Engine Block Heater Plug Use heater to maintain a constant engine coolant temperature. To turn on heater, connect heater plug to 120 volts AC receptacle. Coolant Heater Specifications Watts Volts ±10% 400 120 ! Do not run engine while engine block heater is on. NOTICE −In extremely cold weather, heater should be connected to 120 volts AC receptacle when engine is warm. ! The area near the engine block heater gets hot. Disconnect plug to turn off heater. 1 Coolant Heater1 2012−05 803 562 / Ref. 803 145 Notes OM-262 506 Page 40 Complete Parts List is available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles 2 1 3 4 5 245 609 ! ! 1 Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacle to power life support equipment. Unplug power cord before attempting to service accessories or tools. 120 V 20 A AC GFCI Receptacles GFCI1 And GFCI2 ! Test GFCI monthly. See Section 7-3 for GFCI information and for resetting and testing procedures. overload. If CB5 opens, the receptacles do not work. Place CB5 switch in On position to reset circuit breaker. 2 240 V 50 A AC Receptacle RC11 If a supplementary protector continues RC11 supplies 60 Hz single-phase power at weld/power speed. Maximum output from RC11 is 10 kVA/kW. 3 Supplementary Protector CB4 4 Supplementary Protector CB6 5 Supplementary Protector CB5 GFCI1 and GFCI2 supply 60 Hz single-phase power at weld/power speed. See Section 7-3 for GFCI information and for resetting and testing procedures. CB4 protects GFCI2 and CB6 protects GFCI1 from overload. If a supplementary protector opens, the receptacle does not work. Press button to reset. Maximum output from these receptacles is 2.4 kVA/kW. Supplementary protector CB5 protects receptacles and the generator winding from to open, contact Factory Authorized Service Agent. Generator power decreases as weld output increases. Combined output of all receptacles is limited to the 10 kVA/kw rating of the generator. EXAMPLE: If 15 A is drawn from each 120 V receptacle , only 26 A is available at the 240 V receptacle: 2 x (120 V x 15 A) + (240 V x 26 A) = 10.0 kVA/kW OM-262 506 Page 41 Complete Parts List is available at www.MillerWelds.com 7-2. Export Auxiliary Power Receptacles 1 3 2 4 5 256 593-A ! Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCIprotected extension cord. Do not use GFCI receptacle to power life support equipment. ! Unplug power cord before attempting to service accessories or tools. 1 2 switch in On position to reset circuit breaker. 3 Supplementary Protector CB4 CB4 protects GFCI1 from overload. If supplementary protector opens, the receptacle does not work. Press button to reset. 4 110V 20 A AC Receptacle GFCI1 220V 16 A AC Receptacle RC11 5 110V16A AC Receptacle RC12 Earth Leakage Circuit Breaker ELCB1 Receptacles supply 50/60 Hz single-phase power. ELCB1 protects receptacle from overload and earth leakage fault. If circuit breaker opens, the receptacle does not work. Place OM-262 506 Page 42 Maximum combined output of all receptacles is 4 kVa/kW. ! Test GFCI monthly. See Section 7-3 for GFCI information and for resetting and testing procedures. At least once a month, run engine at weld/power speed and press test button to verify ELCB1is working properly. If a supplementary protector or circuit breaker continues to open, contact Factory Authorized Service Agent. Generator power decreases as weld output increases. Complete Parts List is available at www.MillerWelds.com 7-3. GFCI Receptacle Information, Resetting And Testing 1 2 3 4 ! Test and reset GFCI only at Run speed. RotGFCI1 2014−09 ! Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCIprotected extension cord. Do not use GFCI receptacle to power life support equipment. ! Unplug power cord before attempting to service accessories or tools. 1 120 V 20 A AC GFCI Receptacle 2 GFCI Receptacle Test Button 3 GFCI Receptacle Reset Button 4 GFCI Indicator Light (LED) GFCI Receptacles GFCI receptacles protect the user from electric shock if a ground fault occurs in equipment connected to the receptacle. A ground fault occurs when electrical current takes the shortest path to ground (which could be through a person) rather than follow its intended safe path. If a ground fault is detected, the GFCI Reset button pops out, and the circuit opens to disconnect power to the faulty equipment. A GFCI receptacle does not protect against circuit overloads, short circuits, or shocks not related to ground faults. Reset and test GFCI receptacle according to the following procedures. Resetting/Testing GFCI Receptacle ! Test GFCI monthly. See Testing GFCI Receptacle. ! Do not test or reset GFCI receptacles at idle speed/low voltage or the GFCI will be damaged and not provide protection from electric shock caused by a ground fault. ! ! If LED blinks, stop using GFCI receptacle and have it replaced by a Factory Authorized Service Agent. Extension cords with bad insulation or of extended length can allow enough leakage current to trip the GFCI circuit. Reset and test as follows. Resetting GFCI Receptacles If a GFCI fault occurs, stop engine and disconnect equipment from GFCI receptacle. Check for damaged or wet tools, cords, plugs, etc. connected to the receptacle. Start engine and operate at Run (weld/ power) speed. Press GFCI Reset button. Reconnect equipment to GFCI receptacle. If GFCI Reset button pops out again, check the equipment and repair or replace if faulty. Testing GFCI Receptacles GFCI testing must be done with engine running at Run (weld/power) speed. Start engine and operate at Run (weld/ power) speed. Press the GFCI Test button. The GFCI Reset button should pop out. Press the GFCI Reset button. Have GFCI replaced by a Factory Authorized Service Agent if any of the following occur: GFCI does not trip when tested LED blinks GFCI does not reset. OM-262 506 Page 43 Complete Parts List is available at www.MillerWelds.com SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Maintenance Label (CAT) j 237 382-G OM-262 506 Page 44 Complete Parts List is available at www.MillerWelds.com 8-2. Maintenance Label (Mitsubishi) j 239 396-K OM-262 506 Page 45 Complete Parts List is available at www.MillerWelds.com 8-3. Routine Maintenance ! Recycle engine fluids. = Check = Change = Clean * To be done by Factory Authorized Service Agent Every 8 Hours Stop engine before maintaining. See Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. = Replace Reference Section 5-6, 5-7, and, 5-8 See engine manual for fuel specifications. Coolant Level Fuel Level Oil Level Every 50 Hours Oil, Fuel Spills Clean unit exterior, including stainless steel, frequently to prevent rust and corrosion. Weld Terminals Every 100 Hours Section 8-6 Battery Terminals Air Cleaner Hoses Every 250 Hours CAT Every 500 Hours Mitsubishi Unreadable Labels Engine Manual, Section 8-7, 8-10 1/2 in. (13 mm) NOTICE − Change engine oil and filter after initial 50 to 75 hours of use. See engine manual for oil specifications Air Cleaner Element Oil Oil Filter Fan Belt Tension Every 500 Hours All Models Spark Arrestor FUEL Section 8-10 SLUDGE Weld Cables Radiator Thermostat Every 1000 Hours Fuel Filters Drain Sludge Section 5-6, 8-8, and Engine Manual OR Slip Rings* Brushes* Valve Clearance* Inside Unit Radiator Fluid Level Every 2000 Hours Injectors* Caterpillar Corporate Headquarters 100 North East Adams Street Peoria, Illinois USA 61629 (309) 675−1000 Mitsubishi Engine North America 1250 Greenbriar Dr., Suite E Addison, IL 60101 630−268−0750 http://www.cat.com/engines Http://www.mitsubishi−engine.com Cat Dealer Locator: Use website to find local engine service facility. Use web site to locate closest dealer. For international information, use: Http://www/mhi/co/jp/global/network 8-4. Adjusting Engine Speed NOTICE − The engine is electronically governed. Engine speed adjustment must be done by an engine Factory Authorized Service Agent. Tampering with adjustments may affect engine warranty. OM-262 506 Page 46 Complete Parts List is available at www.MillerWelds.com 8-5. Checking Generator Brushes 1 Replace Assembly if Brushes are Damaged ! Stop engine and let cool. 1 Generator Brush Assembly Mark and disconnect leads at brush holder assembly. Remove assembly. Press on brush to be sure springs compress. 1 Replace assembly if brushes are damaged or if brush material is at or near minimum length. Check length from brushholder surface. New Length: 5/8 in. (16mm) Minimum Length: 1/4 in. (6.5mm) GenBrush2 2014-10 / Ref 205 725 8-6. Servicing Air Cleaner Blow Keep nozzle 2 in. (51 mm) from element. 1 2 3 4 Inspect Optional 5 aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 226 386-B ! ment, we strongly recommend installing an optional safety element to provide additional engine protection. Never clean a safety element. Replace the safety element after servicing the primary element three times. Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged element is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding capacity of the filter is reduced with each cleaning. The chance of dirt reaching the clean side of the filter while cleaning and the possibility of filter damage makes cleaning a risk. Consider the risk of unwarrantable equipment damage when determining whether to clean or replace the primary element. If you decide to clean the primary ele- Clean or replace primary element if dirty (see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six cleanings. 1 Housing 2 Safety Element (Optional) 3 Primary Element 4 Dust Cap 5 Dust Ejector To clean air filter: Wipe off cap and housing. Remove cap and dump out dust. Remove element(s). Wipe dust from inside cap and housing with damp cloth. Reinstall safety element (if present). Reinstall cap. NOTICE − Do not clean housing with air hose. Clean primary element with compressed air only. Air pressure must not exceed 100 psi (690 kPa). Use 1/8 in. (3 mm) nozzle and keep nozzle at least 2 in. (51 mm) from inside of element. Replace primary element if it has holes or damaged gaskets. Reinstall primary element and cap (dust ejector down). OM-262 506 Page 47 Complete Parts List is available at www.MillerWelds.com 8-7. Inspecting And Cleaning Optional Spark Arrestor Muffler ! Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhaust pipe with fireproof material. ! 3 Stop engine and let cool. Reinstall cleanout plug. 1 Tools Needed: 2 3/8 in. 803 582 / Ref. 245 609 8-8. Servicing Engine Cooling System ! Stop engine and let cool. 4 Radiator Cap Cover 5 Radiator Draincock 6 Coolant Recovery Tank Change coolant according to engine manual. Add coolant according to engine maintenance label. 1 Check coolant level in recovery tank daily. If necessary, add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels. If recovery tank coolant level was low, also check coolant level in radiator. Add coolant if level is below bottom of radiator filler neck. 2 3 Coolant1 2010−04 / Ref. 907 427-6 OM-262 506 Page 48 Complete Parts List is available at www.MillerWelds.com 8-9. Overload Protection ! Stop engine. When a circuit breaker, supplementary protector, or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. 1 Fuse F1 F1 protects the stator exciter winding from overload. If F1 opens, weld and generator power is low or stops entirely. 2 1 3 Circuit Breaker CB1 (Not Shown) Supplementary Protector CB2 4 Supplementary Protector CB3 5 Supplementary Protector CB8 6 Circuit Breaker CB9 CB1 protects the engine battery circuit. If CB1 opens, the engine will not crank. CB1 automatically resets when the fault is corrected. CB2 protects the engine wiring harness. If CB2 opens, the engine will not crank. CB3 protects part of the weld control wiring harness. If CB3 opens, weld and generator power output stops. 3 4 6 CB8 protects the 24 volt AC output to remote receptacle RC14. If CB8 opens, 24 volt output to RC14 stops. Press button to reset supplementary protector. CB9 protects the throttle solenoid against overload. If CB9 opens, the engine does not automatically idle down. Check the linkage and solenoid. CB9 automatically resets. 5 803 562 / 803 566 OM-262 506 Page 49 Complete Parts List is available at www.MillerWelds.com 8-10. Servicing Fuel And Lubrication Systems ! Stop engine and let cool. ! After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel. 1 2 3 Oil Filter Oil Drain Valve And Hose Oil Fill Cap 4 Primary Fuel Filter 5 Secondary Fuel Filter 6 Fuel Tank Sludge Drain Valve 7 Fuel Filter Retaining Ring To change oil and filter: Route oil drain hose and valve through hole in base. See engine manual and engine maintenance label for oil/filter change information. 6 2 Tools Needed: CAT Engine 4 3 5 1 803 563 / Ref 214 777−E OM-262 506 Page 50 Complete Parts List is available at www.MillerWelds.com To replace primary fuel filter: For CAT Engines: Turn filter counterclockwise. Remove filter. For Mitsubishi Engines: Turn filter retaining ring counterclockwise to remove. Pull filter straight down to remove. Fill new filter with fresh fuel. Apply thin coat of fuel to gasket on new filter. For CAT Engines: Install new filter and turn clockwise. For Mitsubishi Engines: Install new filter and reinstall retaining ring. Mitsubishi Engine 4 Bleed air from fuel system according to engine manual. 3 Inspect fuel lines, and replace if cracked or worn. To drain water from fuel system: See engine manual. To replace secondary fuel filter: Note direction of fuel flow as indicated by arrow on side of filter. Remove fuel line clamps and disconnect fuel lines from fuel filter. Replace filter , reconnect fuel lines, and reinstall clamps. 5 To drain sludge from fuel tank: 1 7 ! Beware of fire. Do not smoke and keep sparks and flames away from drained fuel. Dispose of drained fuel in an environmentally-safe manner. Do not leave unit unattended while draining fuel tank. ! Properly lift unit and secure in a level position. Use adequate blocks or stands to support unit while draining fuel tank. Attach 1/2 ID hose to drain valve. Put metal container under drain, and use screwdriver to open sludge drain valve. Close valve when sludge has drained. Remove hose. Close door. 803 581 / 907 427−6 OM-262 506 Page 51 Complete Parts List is available at www.MillerWelds.com 8-11. Voltmeter/Ammeter Help Displays 1 HL.P 20 HL.P 21 HL.P 22 HL.P 23 HL.P 25 2 3 4 5 245 609 Use the Voltmeter/Ammeter help displays to diagnose and correct fault conditions. When a help code is displayed normal- ly weld output has stopped but generator power output may be okay. To reset help displays, stop unit and then restart. See item 6 below to reset Help 25 display. 1 Help 20 Display Indicates a failure of meter display module PC2, or the wiring between PC2 and main control module PC1. If this display is shown, have Factory Authorized Service Agent check PC1, PC2, and the wiring between PC1 and PC2. 2 Help 21 Display Indicates thermal protector TP1 on stabil- izer Z1 has opened (Z1 overheated) or thermistor TH1 on the main rectifier heat sink has failed. If this display is shown, have, allow unit to cool and reduce duty cycle. If unit does not reset after cooling, have Factory Authorized Service Agent check TH1, and the wiring between TH1 and PC1. 3 Help 22 Display Indicates the rectifier heat sink has overheated. If this display is shown, check generator cooling system and/or reduce duty cycle. Keep engine access door closed when running to maintain proper cooling air flow past rectifier. Allow unit to cool before restarting. If problem continues, have Factory Authorized Service Agent check unit. 4 Help 23 Display Can indicate a complete loss of generator excitation, auxiliary power output, and weld output or a failure of one of the rectifier output SCRs. If generator output is lost, see trouble “No generator power or weld output.” in section 8-14B. If generator output is okay, have Factory Authorized Service Agent check the rectifier SCRs. 5 Help 25 Display Indicates a remote device connected to Remote Receptacle RC14 may be faulty. Help 25 is also displayed whenever a remote device has been connected to RC14 and then disconnected. Clear fault by stopping and restarting the unit or by turning Process/Contactor switch to another position. If problem continues, have Factory Authorized Service Agent check the remote device, filter board PC6, and main control module PC1. 8-12. Maintaining Stainless Steel (Models With Optional Package) Stainless steel is very resistant to rust and corrosion; however, it must be kept clean to ensure rust and corrosion resistance. Units used in corrosive environments (chlorine or salt water environment for example) should be cleaned with mild soap and water frequently. If dirt build−up occurs, use a stainless steel cleaner to remove build−up. With proper maintenance, stainless steel maintains its luster and appearance. 8-13. Battery Maintenance Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and before being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open−circuit voltage drops to 12.4 volts DC when measured across the battery terminals. OM-262 506 Page 52 Complete Parts List is available at www.MillerWelds.com 8-14. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-11). A. Welding Trouble Remedy No weld output; generator power output Have Factory Authorized Service Agent check main rectifier and main control module PC1. okay at AC receptacles. Reset supplementary protector CB8 (see Section 8-9). Check for faulty remote device connected to RC14. Check and secure connections to Remote Control receptacle RC14 (see Section 5-12). Check Voltmeter/Ammeter help displays (see Section 8-11). No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up. put at AC receptacles. Reset supplementary protector CB3. (see Section 8-9). Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service Agent check the field excitation circuit. Check Voltmeter/Ammeter help displays (see Section 8-11). Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit. Erratic weld output. Check and tighten connections inside and outside unit. Be sure connection to work piece is clean and tight. Use dry, properly stored electrodes. Remove excessive coils from weld cables. Have Factory Authorized Service Agent check brushes and slip rings. High weld output. Have Factory Authorized Service Agent check main control module PC1 and hall device HD1. Low weld output. Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service Agent check the rotor. Low open-circuit voltage. Have Factory Authorized Service Agent check main control module PC1, field excitation circuit, and main rectifier. No remote fine amperage control. Repair or replace remote control device. Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 5-12). No 24 volt AC output at Remote recep- Reset supplementary protector CB8 (24 volt) (see Section 8-9). tacle RC14. OM-262 506 Page 53 Complete Parts List is available at www.MillerWelds.com B. Standard Generator Power Trouble Remedy No generator power output at AC recep- Reset receptacle supplementary protectors (see Section 7-1 or 7-2).Check and reset GFCI receptacles tacles; weld output okay. if necessary (see Section 7-3). No generator power or weld output. Disconnect equipment from generator power receptacles during start-up. Check fuse F1, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check field excitation circuit. Reset supplementary protector CB3 (see Section 8-9). Check Voltmeter/Ammeter help displays (see Section 8-11). Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit. High output at generator power AC re- Have Factory Authorized Service Agent check field excitation circuit. ceptacles. Low output at generator power AC re- Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service ceptacles. Agent check the rotor. C. Engine Trouble Engine will not crank. Remedy Check battery, and replace if necessary. It may be necessary to remove oil filter to replace battery. Check battery connections and tighten if necessary. Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-9). Have Factory Authorized Service Agent check engine wiring harness and components. Reset supplementary protector CB2 (see Section 8-9). Check engine wiring harness plug connections. Have Factory Authorized Service Agent check Engine Control switch S1, Fuel/Hour gauge FUEL/HM, and control relay CR2. Engine cranks but does not start. Check fuel level. Check battery and replace if necessary. Check engine charging system according to engine manual. Have Factory Authorized Service Agent check control relay CR1, Fuel/Hour gauge FUEL/HM, fuel solenoid FS1, and the fuel pump. Air in fuel system. See engine manual. Engine hard to start in cold weather. Use Preheat switch S4 (see Section 6-2). Keep battery in good condition. Store battery in warm area off cold surface. Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for fuel information. Use correct grade oil for cold weather (see engine manual). Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow plug. Engine suddenly stops. Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high (see Sections 5-6, 5-7, and, 5-8). Check fuel/hour meter for indication of shutdown. Reset supplementary protector CB2 and/or clear fault causing circuit breaker CB1 to trip (see Section 8-9). Have Factory Authorized Service Agent check engine alternator, engine harness, fuel solenoid FS1, and the fuel pump. Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, integrated rectifier SR2, fuel solenoid FS1, and the fuel pump. See engine manual. OM-262 506 Page 54 Complete Parts List is available at www.MillerWelds.com Trouble Remedy Engine slowly stopped and cannot be restarted. Check fuel level. Check fuel/hour meter for indication of shutdown. Check engine air and fuel filters (see Sections 8-6 and 8-10). See engine manual. Battery discharges between uses. Turn Engine Control switch off when unit is not running. Clean top of battery with baking soda and water solution; rinse with clear water. Recharge or replace battery if necessary. It may be necessary to remove oil filter to replace battery. Periodically recharge battery (approximately every 3 months). Engine idles, but does not come up to weld speed. Have engine Factory Authorized Service Agent check engine speed control system. Engine does not run at idle speed. Have engine Factory Authorized Service Agent check engine speed control system. Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 11). wetstacking occurs. SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Dia. Mkgs. Part No. . . . . . . . . . . . F1 . . . . . 085874 . . . . . . . . . . . . . . . . . . . . . . 244290 . . . . . . . . . . . . . . . . . . . . . . 242883 . . . . . . . . . . . . . . . . . . . . . . 252782 . . . . . . . . . . . . . . . . . . . . . . 252781 . . . . . . . . . . . . . . . . . . . . . . 213858 . . . . . . . . . . . . . . . . . . . . . . 242882 . . . . . . . . . . . . . . . . . . . . . . 197676 . . . . . . . . . . . . . . . . . . . . . . 217686 . . . . . . . . . . . . . . . . . . . . . . 202166 . . . . . . . . . . . . . . . . . . . . . . 213858 . . . . . . . . . . . . . . . . . . . . . . 217687 . . . . . . . . . . . . . . . . . . . . . . 197676 . . . . . . . . . . . . . . . . . . . . ♦197679 . . .............................. Description Quantity Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . Brushholder Assembly, Generator w/Leads . . . . . . . . . . . . . . . . . . . . . . . . . Belt, Alternator (Mitsubishi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter Kit,Mitsubishi (S4l2) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . Filter, Lube Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt, Alternator (CAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter, Oil (CAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 (CAT) . . . . . . . . . . . . . . . . . . . . Filter, Fuel Spin−on (CAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Element, Air Cleaner (CAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery, Stor 12v 500 Crk 75 Rsv Gp 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ♦Optional To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-262 506 Page 55 SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welder/Generator OM-262 506 Page 56 262402-B OM-262 506 Page 57 Figure 10-2. Circuit Diagram For Export Model Welder/Generator OM-262 506 Page 58 262 472-B OM-262 506 Page 59 SECTION 11 − RUN-IN PROCEDURE run_in1 2014−09 NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary. 11-1. Wetstacking NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. 1 Welder/Generator Run diesel engines near rated voltage and current during run-in period to properly seat piston rings and prevent wetstacking. See nameplate, rating label, or specifications section in this manual to find rated voltage and current. 2 NOTICE − Do not idle engine longer than necessary. Piston rings only seat correctly if engine runs at weld/ power rpm, and the welder/generator is kept loaded during run-in. 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. 1 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 additional engine run-in information. OM-262 506 Page 60 11-2. Run-In Procedure Using Load Bank Or Resistance Grid 2 1 7 4 3 5 + 6 S-0683 / S-0684 ! Stop engine. ! Do not touch hot exhaust pipe, engine parts, or load bank/grid. ! Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. 1 Load Bank Turn all load bank switches Off. If needed, connect load bank to 115 volts ac wall receptacle or generator auxiliary power receptacle. 2 Welder/Generator Place A/V range switch in maximum position, A/V control in minimum position, and Output Selector switch (if present) in either DC position. 3 Weld Cables 4 Resistance Grid Use grid sized for generator rated output. Turn Off grid. 5 Voltmeter 6 Clamp-On Ammeter Connect voltmeter and ammeter as shown, if not provided on generator. Start engine and run for several minutes. For Load Bank Set load bank switches and then adjust generator A/V control so load equals rated voltage and current of generator (see nameplate, rating label, or the specifications section in this manual). For Resistance Grid Set grid switches and then adjust generator A/V control so load equals rated voltage and current of the generator (see nameplate, rating label, or the specifications section in this manual). Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly. NOTICE − Check oil level frequently during run-in; add oil if needed. It is recommended to run the welder/generator for two hours minimum and up to four hours under load. Place A/V control in minimum position, then shut down load bank or grid to remove load. Run engine several minutes at no load. ! Stop engine and let cool. 7 Engine Exhaust Pipe Repeat procedure if wetstacking is present. OM-262 506 Page 61 SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 12-1. Selecting Equipment 1 2 1 3 Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Be sure equipment has double insulated symbol and/or wording on it. ! 2 Do not use 2-prong plug unless equipment is double insulated. 3 OR gen_pwr 2014−09 − ST-800 577 12-2. Grounding Generator To Truck Or Trailer Frame 1 2 GND/PE 3 800 652-D ! ! 1 2 Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators. Equipment Grounding Terminal (On Front Panel) Grounding Cable (Not Supplied) OM-262 506 Page 62 3 Metal Vehicle Frame frame. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown. Connect cable from equipment ground terminal to metal vehicle frame. Use #8 AWG or larger insulated copper wire. Electrically bond generator frame to vehicle frame by metal-to-metal contact. ! Bed liners, shipping skids, and some running gear insulate the welder/generator from the vehicle ! Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. 12-3. Grounding When Supplying Building Systems 1 2 1 Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. 2 3 GND/PE Ground Device Use ground device as stated in electrical codes. 2 3 ! Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. ! Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators. ST-800 576-B 12-4. How Much Power Does Equipment Require? 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power. 2 3 2 1 Non-Resistive Load Equipment with a motor is a non-resistive load and requires approximately six times more power while starting the motor than when running (see Section 12-8). VOLTS 115 AMPS 4.5 Hz 60 3 Rating Data Rating shows volts and amperes, or watts required to run equipment. Amperes x Volts = Watts Example 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. 3 4.5 A x 115 V = 520 W The load applied by the drill is 520 watts. Example 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load. (3 x 200W) + 520 W = 1120 W The total load applied by the three flood lamps and drill is 1120 watts. S-0623 OM-262 506 Page 63 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty Rating Starting Watts Running Watts 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP 1/3 HP 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 5 HP 7-1/2 HP 10 HP 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP 800 1225 1600 2100 3175 2020 3075 4500 6100 8200 10550 15900 23300 8100 23300 35000 46700 1000 1400 1850 2400 3500 300 500 600 700 875 720 975 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 400 550 650 800 1100 12-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std. (e.g. Conveyors, Feed Augers, Air Compressors) High Torque (e.g. Barn Cleaners, Silo Unloaders, Silo Hoists, Bunk Feeders) 3-1/2 cu. ft. Mixer High Pressure 1.8 Gal/Min Washer 2 gal/min 2 gal/min Refrigerator or Freezer Shallow Well Pump Sump Pump OM-262 506 Page 64 Rating 1/4 HP 1/2 HP 3/4 HP 2 HP 1/3 HP 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 5 HP 7-1/2 HP 10 HP 1/2 HP 500 PSI 550 PSI 700 PSI 1/3 HP 1/2 HP 1/3 HP 1/2 HP Starting Watts Running Watts 1000 1650 3400 4400 2900 10500 1720 2575 4500 6100 8200 10550 15900 23300 8100 23300 35000 46700 3300 3150 4500 6100 3100 2150 3100 2100 3200 1000 650 1000 1400 1100 2800 720 975 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 1000 950 1400 1600 800 750 1000 800 1050 12-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet & Dry Vac Rating Starting Watts Running Watts 1/4 in. 3/8 in. 1/2 in. 6-1/2 in. 7-1/4 in. 8-1/4 in. 9 in. 10 in. 14 in. 6 in. 8 in. 10 in. 1/2 HP 1 HP 1-1/2 HP 2 HP 1-1/2 HP, 12 in. 2 HP, 14 in. Standard 9 in. Heavy Duty 12 in. 1/3 HP 18 in. HID Metal Halide Mercury Sodium Vapor 400 GPH 900 GPH 3/4 HP, 16 in. 1 HP, 20 in. 1/2 HP 3/4 HP 1 HP 1/4 HP 1.7 HP 2-1/2 HP 350 400 600 500 900 1400 4500 6300 2500 1720 3900 5200 3000 6000 8200 10500 1100 1100 350 500 2100 400 125 313 1000 1400 1250 600 900 4500 6100 3150 4500 6100 1900 900 1300 350 400 600 500 900 1400 1500 1800 1100 720 1400 1600 1000 1500 2200 2800 1100 1100 350 500 700 400 100 250 1000 200 500 1400 1600 950 1400 1600 700 900 1300 OM-262 506 Page 65 12-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0 1 2 3 4 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: 4 1 3 AC MOTOR VOLTS 230 AMPS 2.5 CODE M Hz 60 HP 1/4 PHASE 1 2 Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage. Step 2: Find Motor HP and Volts. Step 3: Determine starting amperage (see example). Welder/generator amperage output must be at least twice the motor’s running amperage. (kVA/HP x HP x 1000) / Volts = Starting Amperage Example: Calculate starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230, HP = 1/4, kVA/HP = 11.2 (11.2 x 1/4 x 1000) / 230 = 12.2A Starting the motor requires 12.2 amperes. S-0624 12-9. How Much Power Can Generator Supply? 1 Limit Load To 90% Of Generator Output Always start non-resistive (motor) loads in order from largest to smallest, and add resistive loads last. 2 1 2 5 Second Rule If motor does not start within 5 seconds, turn off power to prevent motor damage. Motor requires more power than generator can supply. Ref. ST-800 396-A / S-0625 OM-262 506 Page 66 12-10. Typical Connections To Supply Standby Power 1 2 Utility Electrical Service Transfer Switch Fused Disconnect Switch (If Required) Have only qualified persons perform these connections according to all applicable codes and safety practices. ! Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes. Customer-supplied equipment 4 3 ! Welding Generator Output is required if generator will supply standby power during emergencies or power outages. 1 Utility Electrical Service 2 Transfer Switch (Double-Throw) 5 Essential Loads Switch transfers the electrical load from electric utility service to the generator. Transfer load back to electric utility when service is restored. Install correct switch (customersupplied). Switch rating must be same as or greater than the branch overcurrent protection. 3 Fused Disconnect Switch Install correct switch (customersupplied) if required by electrical code. 4 Welder/Generator Output Generator output voltage and wiring must be consistent with regular (utility) system voltage and wiring. Connect generator with temporary or permanent wiring suitable for the installation. Turn off or unplug all equipment connected to generator before starting or stopping engine. When starting or stopping, the engine has low speed which causes low voltage and frequency. 5 Essential Loads Generator output may not meet the electrical requirements of the premises. If generator does not produce enough output to meet all requirements, connect only essential loads (pumps, freezers, heaters, etc. − See Section 12-4). OM-262 506 Page 67 12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) Load (Watts) 5 600 7 840 10 1200 15 4 6 8 10 12 14 350 (106) 225 (68) 137 (42) 100 (30) 400 (122) 250 (76) 150 (46) 100 (30) 62 (19) 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15) 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9) 20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9) 25 3000 175 (53) 112 (34) 62 (19) 37 (11) 30 3600 150 (46) 87 (26) 50 (15) 37 (11) 35 4200 125 (38) 75 (23) 50 (15) 40 4800 112 (34) 62 (19) 37 (11) 45 5400 100 (30) 62 (19) 50 6000 87 (26) 50 (15) *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) Load (Watts) 5 1200 7 1680 10 2400 15 4 8 10 12 14 700 (213) 450 (137) 225 (84) 200 (61) 800 (244) 500 (152) 300 (91) 200 (61) 125 (38) 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31) 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18) 20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18) 25 6000 350 (107) 225 (69) 125 (38) 75 (23) 30 7000 300 (91) 175 (53) 100 (31) 75 (23) 35 8400 250 (76) 150 (46) 100 (31) 40 9600 225 (69) 125 (38) 75 (23) 45 10,800 200 (61) 125 (38) 50 12,000 175 (53) 100 (31) *Conductor size is based on maximum 2% voltage drop OM-262 506 Page 68 6 Effective January 1, 2015 (Equipment with a serial number preface of MF or newer) Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original * Batteries retail purchaser that new Miller equipment sold after the effective * Bernard Guns (No Labor) date of this limited warranty is free of defects in material and * Tregaskiss Guns (No Labor) workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts * Accessory (Kits) OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. * Canvas Covers * Induction Heating Coils and Blankets, Cables, and Within the warranty periods listed below, Miller will repair or replace Non-Electronic Controls any warranted parts or components that fail due to such defects in * M-Guns material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will * MIG Guns and Subarc (SAW) Torches provide instructions on the warranty claim procedures to be * Remote Controls and RFCS-RJ45 followed. If notification is submitted as an online warranty claim, the * Replacement Parts (No labor) claim must include a detailed description of the fault and the * Roughneck Guns troubleshooting steps taken to identify failed components and the * Spoolmate Spoolguns cause of their failure. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed twelve months after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor. 1. 2. 3. 4. 5 Years Parts — 3 Years Labor * Original Main Power Rectifiers Only to Include SCRs, Diodes, and Discrete Rectifier Modules 3 Years — Parts and Labor * Auto-Darkening Helmet Lenses (Except Classic Series) (No Labor) * Engine Driven Welder/Generators (NOTE: Engines are Warranted Separately by the Engine Manufacturer.) * Inverter Power Sources (Unless Otherwise Stated) * Plasma Arc Cutting Power Sources * Process Controllers * Semi-Automatic and Automatic Wire Feeders * Transformer/Rectifier Power Sources 2 Years — Parts and Labor * Auto-Darkening Helmet Lenses − Classic Series Only (No Labor) * Fume Extractors − Capture 5, Filtair 400 and Industrial Collector Series 1 Year — Parts and Labor Unless Specified * Automatic Motion Devices * CoolBelt and CoolBand Blower Unit (No Labor) * Desiccant Air Dryer System * External Monitoring Equipment and Sensors * Field Options (NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.) * RFCS Foot Controls (Except RFCS-RJ45) * Fume Extractors − Filtair 130, MWX and SWX Series * HF Units * ICE/XT Plasma Cutting Torches (No Labor) * Induction Heating Power Sources, Coolers (NOTE: Digital Recorders are Warranted Separately by the Manufacturer.) * LiveArc Welding Performance Management System * Load Banks * Motor-Driven Guns (except Spoolmate Spoolguns) * PAPR Blower Unit (No Labor) * Positioners and Controllers * Racks * Running Gear/Trailers * Spot Welders * Subarc Wire Drive Assemblies * Water Coolant Systems * TIG Torches (No Labor) * Wireless Remote Foot/Hand Controls and Receivers * Work Stations/Weld Tables (No Labor) Miller’s True Blue® Limited Warranty shall not apply to: 1. 2. 3. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.) Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment. MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. miller_warr 2015-01 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams For International Locations Visit www.MillerWelds.com Welding Process Handbooks To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. ORIGINAL INSTRUCTIONS − PRINTED IN USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 © 2015 Miller Electric Mfg. Co. 2015−01
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