Miller BLUE FIRE 180 User manual

Miller BLUE FIRE 180 User manual
 February 1997 Form: OM-484
= Effective With Serial No. KG082453
Miller
Owner’s Manual
Blue Fire™ 180
CC/DC Welding Generator For SMAW Welding
Rated Welding
Output
150 A, 26 V DC, 35% Duty Cycle, 50 Hz
135 A, 25.4 V DC, 60% Duty Cycle, 50 Hz
125 À, 25 V DC, 100% Duty Cycle, 50 Hz
155 À, 26.2 V DC, 35% Duty Cycle, 60 Hz
140 À, 25.6 V DC, 60% Duty Cycle, 60 Hz
125 À, 25 V DC, 100% Duty Cycle, 60 Hz
Amperage Range 45 — 160
Max. Open-Circuit 80
Voltage DC
Auxiliary Power Single-Phase, 3 kVA/KW, 27/14 A, 110/220 Y AC, 50 Hz
Rating Single-Phase, 3.2 kVA/KW, 27/13 A, 120/240 V AC, 60 Hz
Engine Honda GX390 Air-Cooled, One-Cylinder, 13 HP Gasoline Engine
Fuel Capacity
1.7 US gal (6.4 L)
Sound Power
100 Lwa
Average Sound Level
80 dB(A) At 23 ft (7 m)
ST-801 287
© 1997 MILLER Electric Mfg. Co. PRINTED IN USA
|
MILLER'S TRUE BLUE® LIMITED WARRANTY
Effective January 1, 1997
(Equipment with a serial number preface of “KH” or newer)
This limited warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees
or warranties expressed or implied.
LIMITED WARRANTY — Subjectto the terms and conditions below, MILLER Electric Mfg. Co., Appleton, Wiscon-
sin, warrants to its original retail purchaser that new MILLER equipment sold after the effective date of this limited
warranty is free of defects in material and workmanship at the time itis shipped by MILLER. THIS WARRANTY |S
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRAN-
TIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed betow, MILLER will repair or replace any warranted parts or components that fail
due to such defects in material or workmanship, MILLER must be notified in writing within thirty (30) days of such
defect or failure, at which time MILLER will provide instructions on the warranty claim procedures to be followed,
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 date that the equipment was delivered to the original
retai! purchaser, or one year after the equipment is sant to a North American distributor or sighteen months after
the equipment is sent to an Intemational distributor.
1. 5 Years Parts — 3 Years Labor
*
Original main power rectifiers
* inverters (input and output rectifiers onty)
2. 3 Years — Parts and Labor
* TransformerRectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
" Intellitig
* Robots {1 year labor)
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manufacturer.)
3. 1 Year — Parts and Labor
* Motor Driven Guns
Process Controllers
* IHPS Power Sources
Water Coolant Systems
* HF Units
* Grids
* Spot Welders
* Load Banks
SDX Transformers
Miller Cyclomatic Equipment
* Running Gear/Trailers
* Plasma Cutting Torches (except APT, ZIPCUT á PLAZCUT Models)
Deutz Engines (outside North America)
* Field Options
(NOTE: Field options are covered under True Blue® for the remaining warranty period of the product
they are installed in, or for a minimum of one year — whichever is greater.)
4, $6 Months — Batterles
5. 90 Days — Parts and Labor
* MIG Guns/TIG Torches
* APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches
Remote Controls
Accessory Kits
* Replacement Parts (No labor)
MILLER'S True Blue® Limited Warranty shall not apply to:
1. 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.
2. Consumable components; such as contact tips, cutting nozzles, contactors and relays or parts that fait due to
normal wear.
3. 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 EQUIP-
MENT.
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.
MILLERS 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 transpor-
tation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLU-
SIVE REMEDIES. INNOEVENT 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, OPER-
ATION 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 EQUIP-
MENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Some states inthe U.S.À. do not allow limitations of how long an implied warranty fasts, or the exclusion of inciden-
tal, 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.
WHO DO | CONTACT?
For help, To file a claim for loss or Miller Electric Mfg. Co.
a contact your distributor damage during shipment, m CALL:
For additional informa- E contact the delivering carrier 414-735-4505
tlon, such as For assistance in filing or
Technical Manuals settling claims, m FAX: |
(Service And Parts) E contact your distributor 800-637-2348 (in USA), or
Lo manufacturers
Circuit And Wirin
Diagrams 9 Transportation Department = WRITE:
Miller Electric Mig. Co.
Process Handbooks PO. Box 1079
Users Guides Appleton, WI 54912 USA
Distributor Directories
m contact your distributor
Always provide Model Name and Serial or Style Number
-
a
miller_warri 1/97
TABLE OF CONTENTS
SECTION 1 — SAFETY PRECAUTIONS rise nenn 1
SECTION 2 — DEFINITIONS . .....eeecnmnnnannoncarracannerevemn es 9
SECTION 3 - INSTALLATION .........eeeeononnvmnenarrcaneean e... 12
SECTION 4 - OPERATION -.....ñeeñeenresmmnnarranennerevernen. 17
SECTION 5 —- OPERATING AUXILIARY EQUIPMENT ............... 19
SECTION 6 — MAINTENANCE AND TROUBLESHOOTING .......... 22
SECTION 7 — ELECTRICAL DIAGRAM .....122000 0000 0e una anus e0 0 27
SECTION 8 — PARTS LIST ..........eeeeeeneanovoenomnenarernmecen: 29
SECTION 1 — SAFETY PRECAUTIONS
safety_rom* 1 4/95
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.
A Marks a special safety message.
F7 Means NOTE; not safety related.
+ This group of symbois means Warning! Watch
Out! possible ELECTRIC SHOCK, MOVING
PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary
actions to avoid the hazards.
1-2. Arc Welding Hazards
4& WARNING
The symbols shown below are used throughout this manual to cali
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 1-5. Read
and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this
unit,
During operation, keep everybody, especially children, away.
OM-484 Page 1
= 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 poweris 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.
1. Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or covers big enough to
prevent any physical contact with the work or ground.
4. 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).
5. Properly install and ground this equipment according to its Owner's Manual and national,
state, and local codes.
6. 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.
7. When making input connections, attach proper grounding conductor first — double-check
connections.
8. Frequently inspect input power cord for damage or bare wiring — replace cord immediately if
damaged — bare wiring can kill.
9. Turn off all equipment when not in use.
10. Do not use worn, damaged, undersized, or poorly spliced cables.
11. Do not drape cables over your body.
12. if earth grounding of the workpiece is required, ground it directly with a separate cable — do
not use work clamp or work cable.
13. Do not touch electrode if you are in contact with the work, ground, or another electrode from
a different machine.
14. Use only well-maintained equipment. Repair or replace damaged paris at once. Maintain
unit according to manual.
15. Wear a safety harness if working above floor level.
16. Keep all panels and covers securely in place.
17. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the
weld as practical.
OM-484 Page 2
atta
A
ARC RAYS can burn eyes and skin; NOISE can damage
hearing; FLYING SLAG OR SPARKS can injure eyes.
= pl Arc rays from the welding process produce intense visible and invisible
(ultraviolet and infrared) rays that can burn eyes and skin. Noise from some
processes can damage hearing. Chipping, grinding, and welds cooling throw off
pieces of metal or slag.
3.
4,
NOISE
1. Use approved ear plugs or ear muffs if noise level is high.
ARC RAYS
2. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when
welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields.
Use protective screens or barriers to protect others from flash and glare; warn others not io
watch the arc.
Wear protective clothing made from durable, flame-resistant material (wool and leather) and
foot protection.
FUMES AND GASES can be hazardous to your health.
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 exhaust at the arc to remove welding fumes and
gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the manufacturer's instruction for
metals, consumables, coatings, cleaners, and degreasers.
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 if necessary, while
wearing an air-supplied respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
OM-484 Page 3
CYLINDERS can explode if damaged.
Shielding 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.
1. Protect compressed gas cylinders from excessive heat, mechanical shocks, 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 shielding gas cylinders, regulators, hoses, and fittings designed for the
specific application; maintain them and associated parts in good condition.
8. Turn face away from valve outlet when opening cylinder valve.
8. Keep protective cap in place over valve except when cylinder is in use or connected for use.
10. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.
№
мо я в о
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.
)
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly
cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can easily go through small
cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden
side,
7. Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly
prepared according to AWS F4.1 (see Safety Standards).
8. 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 and fire
hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
12. Remove any combustibles, such as a butane lighter or matches, from your person before
doing any welding.
OM-484 Page 4
1-3. Engine Hazards
A WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1.
2.
Use equipment outside in open, well-ventilated areas.
If used in a closed area, vent engine exhaust outside and away from any
building air intakes.
2.
3.
4
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1.
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.
Во not overfill tank — allow room for fuel to expand,
Do not spill fuel. If fuel is spilled, clean up before starting engine.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch
loose clothing.
1.
2.
3.
Keep all doors, panels, covers, and guards closed and securely in place.
Stop engine before installing or connecting unit.
Have only qualified people remove guards or covers 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 panels or guards and close doors when servicing is finished and
before starting engine.
hn how N
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
1.
Always wear a face shield when working on a battery.
Stop engine before disconnecting or connecting battery cables.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity {+ and —) on batteries.
OM-484 Page 5
1-4. Additional Installation, Operation, And Maintenance Hazards
A WARNING
MOVING PARTS can cause injury.
1. Before working of generator, remove spark plugs or injectors to keep engine
from kicking back or starting.
2. Block flywheel so thatit will not turn while working on generator components.
FLYING PIECES OF METAL or DIRT can injure eyes.
1. Wear safety glasses with side shields or face shield,
STATIC ELECTRICITY can damage parts on circuit boards.
1. Put on grounded wrist strap BEFORE handling boards or parts.
2. Use proper static-proof bags and boxes to store, move, or ship PC boards.
MAGNETIC FIELDS FROM HIGH CURRENTS can affect
pacemaker operation.
1. Pacemaker wearers keep away.
2. Wearers should consult their doctor before going near arc welding, gouging,
or spot welding operations.
HOT PARTS can cause severe burns.
1. Allow cooling period before maintaining.
2. Wear protective gloves and clothing when working on a hot engine.
FALLING EQUIPMENT can cause serious personal injury and
equipment damage.
1. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other
accessories.
2. Use equipment of adequate capacity to lift unit.
OM-484 Page 6
áA WARNING
READ INSTRUCTIONS.
1. Use only genuine MILLER replacement parts.
2. Reinstall injectors and bleed air from fuel system according to engine
manual.
DO NOT LET ENGINE EXHAUST SPARKS CAUSE FIRE.
1. Use approved engine exhaust spark arrestor in required areas — see
applicable codes.
LOW VOLTAGE AND FREQUENCY CAN DAMAGE electrical
equipment such as MOTORS.
1, Turn off or unplug equipment before starting or stopping engine.
OVERUSE can cause OVERHEATED EQUIPMENT.
1. Allow cooling period.
2. Reduce current or reduce duty cycle before starting to weld again.
3. Follow rated duty cycle.
TILTING OF TRAILER can cause injury.
1. Use tongue jack or blocks to support weight.
2. Properly install welding generator onio trailer according to instructions
supplied with trailer.
BATTERY ACID can BURN SKIN AND EYES.
1. Donottip.
2. Replace damaged battery.
3. Flush eyes and skin immediately with water.
OM-484 Page 7
1-5. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard 249.1, from American Welding Society, 550 N.W.
LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That
Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from
American Welding Society, 5560 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas
Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard
Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office
of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields —
Background Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May
1989): “. . . there is now a very large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly establish that low
frequency magnetic fields can interact with, and produce changes in, biological systems. While
most of this work is of very high quality, the results are complex. Current scientific understanding
does not yet allow us to interpret the evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following procedures:
Keep cables close together by twisting or taping them.
Arrange cables to one side and away from the operator.
Do not coil or drape cables around the body.
Keep welding power source and cables as far away as practical.
п к © N =
Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
The above procedures are also recommended for pacemaker wearers. Consult your doctor for
complete information.
OM-484 Page 8
SECTION 2 — DEFINITIONS
2-1. Manufacturer’s Warning Label Definitions
Warning! Watch Outl
There are possible haz-
ards as shown by the
symbols.
Become trained and
read the instructions
before working on the
. Machine or welding.
1 Electric shock from welding
electrode or wiring can kill.
1.1 Wear dry insulating gloves. Do
not touch electrode with bare
hand. Po not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Disconnect input plug or power
before working on machine.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3 Welding sparks can cause
explosion or fire,
3.1 Keep flammables away from
welding. Do not weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
5 Do not remove or paint over
(cover) the label.
6 Engine fuel plus flames or
sparks can cause fire.
6.1 Do not smoke while fueling or
if near fuel.
6.2 Stop engine before fueling.
6.3 Do not fuel a hot engine.
7 Engine exhaust gases can kill.
7.1 Vent exhaust outside.
7.2 Use unit outside.
2/96 Raf. SA-175 679-A
OM-484 Page 9
2-2. Manufacturer's Rating Label
ПО mp 125 |
26V | 25.4V| 25V
n = 3000 RPM
1~050Hz | 110/220V | 3kVA 27/14A
50A/22V 155A/26.2V |
EM EIC
(WE 125А
26.2V| 25.6V| 25V
n = 3600 RPM
60 Hz | No = 3750 RPM IE
1~ (60 Hz | 120/240V | 3.2kVA | 27/13A
3-177 057-A
OM-484 Page 10
2-3. Symbols And Definitions
JT
. Welding Arc CG Weld/Power Speed
=
A Amperes A | Choke
TA Oil 7, Co Engine
Engine-Driven,
Single-Phase Alternator
With Rectifier
Alternating Current (AC)
Protective Earth (Ground)
Read Instructions
®
>
Фут
[die Speed Fuel
ce Negative Positive
Temperature Circuit Breaker
=== Direct Current Time
1 A Single Phase Rated (A rage ао
U 9 lago Load Rated Welding Current
Rated Idle Speed Duty Cycle
N'
Rated Load Speed Rated No Load Speed
n По
H Z Hertz No Output
h Hours
OM-484 Page 11
SECTION 3 — INSTALLATION
3-1. Installing Welding Generator
TO
it -
Movement Airflow Clearance
18 in
(450 mm)
18 in
(460 mm)
instali1” 3/96 — Ref. ST-800 477-A / Ref ST-151 556 / ST-801 267
3-2. Grounding Generator To Truck Or Trailer Frame
= 1 Generator Base
À 2 Metal Vehicle Frame
К A 3 Equipment Grounding
Terminal
4 Grounding Cable
Use #10 AWG or larger insu-
lated copper wire.
A If unit does not have
1 3 4 GFClI receptacles, use
GFCl-protected exten-
e sion cord.
| OR
©
Electrically bond gener-
ator frame to vehicle
frame by metal-to-metal
contact.
install+" 3/96 — 5-0854
OM-484 Page 12
3-3. Grounding When Supplying Building Systems
Use ground device as
stated in electrical codes. €
1 Equipment Grounding
Terminal
2 Grounding Cable
Use #10 AWG or larger insu-
lated copper wire.
3 Ground Device
A Ground generator to
system earth ground if
supplying power to a
premises (home, shop,
farm) wiring system.
ST-B00 576-B
3-4. Dimensions, Weights, And Operating Angles
Dimensions Weights
Height 27m Un Net (98 ka)
Width 584 ny Ship a 07 co)
Depth | (794 mm)
DM
A Po not exceed operating angles while
running or engine damage will occur.
A Do not move or operate unit where
it could tip.
angles! 3/96 Ref. ST-801 268
OM-484 Page 13
3-5. Fuel Consumption
LITERS/HR.
a
=]
o
1.89
0.95
IMP. GAS/HR.
©
o
La
0.63
0.42
0.21
© U.S. GAL/HA.
md
0.50
0.25
0
0
"60 HZ
3730 RPM
a
|]
A LTT] _50HZ
— 3150 RPM
re
IDLE 1600 RPM
25 50 75 100 125 150 175 200 225 250 275
WELD AMPERES AT 100% DUTY CYCLE
| | | | | | | | | | | |
O 0.5 10 15 20 25 30 35 40 45 5.0 5.5
POWER KVA AT 100% DUTY CYCLE
51-180 760
OM-484 Page 14
3-6. Engine Prestart Checks
Check all fluids daily. Engine
must be cold and on a level
surface.
Engine stops if oil level gets
too low. Engine will not run
until sufficient oil is added.
1
Open valve.
Fuel Valve
Ref. ST-801 268
OM-484 Page 15
3-7. Weld Output Terminals And Selecting Cable Sizes
A ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible,
close together, and down low, such as on the floor. Locate welding opera-
tion 100 meters from any sensitive electronic equipment. Be sure this weld-
ing machine is installed and grounded according to this manual, if interfer-
ence 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.
Weld Output
Terminals
ST-801 270
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
Or Less (45m) | (60m) | (70 т} | {90 т} | (105 т) | (120 т)
10 — 60 —
ong | 80% 100% 10100 Dury Cycle
Cycle Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
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. S-0007-D
OM-484 Page 16
4-1. Controls
SECTION 4 — OPERATION
ZE
il, |e | „@
Wish
1 Engine Switch
Use switch to open ignition
circuit, and to stop engine.
2 Throttle Control Lever
Use lever to select engine
speed. Use 50 Hz or 60 Hz
position for auxiliary power.
Use 60 Hz position for maxi-
mum weld output.
3 Choke Control Lever
Use lever to change engine
air/fuel mix. Move lever to
left if starting a cold engine.
Move lever to right if starting
a warm engine.
4 Starter Handle
To Start: turn engine switch
to On, move throttle lever to
Idle, set choke, and pull
starter handle. Open choke
as engine warms.
To Stop: turn engine switch
to Off.
5 Current Control
Use control to select weld
amperage. Control may be
adjusted while welding.
6 Engine Hour Meter HM
7 Over-Temp/Low Speed
Warning Light
Light goes on and output
stops when generator over-
heats or engine speed is too
low. Output resumes when
generator cools or engine
speed returns to normal.
Ref. ST-B01 268 / ST-801 270-À
OM-484 Page 17
4-2. Duty Cycle
Duty cycle is the percentage
of 10 minutes that unit can
weld at rated load without
overheating.
A Exceeding duty cycle
can damage unit and
Continuous Welding void warranty.
100% Duty Cycle at 125 Amperes DC, 60 Hz
6 Minutes Welding 4 Minutes Resting
60% Duty Cycle at 140 Amperes DC, 60 Hz
3-1/2 Minutes Welding 6-1/2 Minutes Resting
35% Duty Cycle at 155 Amperes DC, 60 Hz
300
250
200
150
100
WELD AMPERES
75
50
10 15 20 2530 40 50 60 70 80 100
% DUTY CYCLE
ST-180 763
OM-484 Page 18
SECTION 5 — OPERATING AUXILIARY EQUIPMENT
5-1. Optional Auxiliary Power Receptacles
\ A
{J
ACH 5
120V
Receptacles supply single-
phase power at weld/power
speed. Total output of recep-
tacles is 3 KVA/KW (50 Hz) or
3.2 KVA/KW (60 Hz),
Example (50 Hz): 7 Ais
drawn from one 230 Y recep-
tacie, 6 A is available at the
other 230 V receptacle:
(230 V x 7 A) + (230 V x 6 A)
= 3 KVA/KW
IF Auxiliary power de-
creases as weld current
increases.
Press button to reset
circuit breaker. If a circuit
breaker continues to
open, see Factory Au-
thorized Service Agent.
1 South American
Receptacle Option
2 230V 15 A AC Recep-
tacles RC1 And RC2
3 Circuit Breakers CB1
And CB2
CB1 and CB2 protect RCT
and RC2 from overoad. If
CB1 or CB2 opens, the re-
ceptacles do not work. 115
volts may still be present at
the receptacles.
Ref. ST-175 644-A / Ref. ST-175 641-A
4 Domestic Receptacle
Option
5 120V 30 A AC Twist-
lock Receptacle RCH
6 120V 15 A AC Recep-
tacle RC2
7 Circuit Breakers CB1
And CB2
CB1 and CB2 protect RCA
and RC2 from overload. If
CB1 or CB2 opens, the re-
ceptacle does not work.
OM-484 Page 19
5-1.
Optional Auxiliary Power Receptacles (Continued)
OEE
= 00
1 U.K. Receptacle
Option
2 32A110V AC
Receptacle RCA
3 16A110VAC
Receptacle RC2
4 Circuit Breakers CB1
Thru CB4
CB1 and CB2 protect RCH
and RC2 from overload. If
CB1 or CB2 opens, RC1 and
RC2 do not work. 110 volts
may still be present at each
receptacie.
CB3 and CB4 each protect
RC2 from overload. If CB3 or
CB4 opens, RC2 dees not
work. 110 volts may still be
present at RC2.
ii
Ref. 57-176 351 / Aef. ST-176 339 / Ref. ST-181 457
5 Australian Receptacle
Option
6 15A230V AC
Receptacles RC1 And
RC2
7 Circuit Breakers CB1
Thru CB4
CB1 and CB2 protect RC1,
and CB3 and CB4 protect
RC2 from overload. If a cir-
cuit breaker opens, the re-
ceptacie does not work. 115
volts may still be present at
the receptacle.
8 120 V Duplex / 240 V
Twistlock Receptacle
Option
9 30 A240 V AC Twist-
lock Receptacle RC1
10 15 À 120 V AC Duplex
Receptacle RC2
11 Circuit Breakers CB1
Ang CB2
CB1 and CB2 protect RCH
and RC2 from overload. If
CB1 or CB2 opens, RC1 and
half of RC2 does not work.
120 volts may still be present
at RC1.
OM-484 Page 20
5-1. Optional Auxiliary Power Receptacles (Continued)
1 European Receptacle
Option
2 South African
Receptacle Option
3 Southeast Asia/
Belgium/Thailand
Receptacle Option
4 16 А230 \ АС
Receptacles RC1 And
RC?
5 (Circuit Breakers CB1
And CB2
CB1 and CB2 protect RCH
and RC2 from overload. If a
circuit breaker opens, the re-
ceptacle does not work.
AG2
230\ ^\_,
ST-175 644 / 51-176 345-A / ST-176 333
OM-484 Page 21
SECTION 6 — MAINTENANCE AND TROUBLESHOOTING
6-1. Routine Maintenance
ap
58
Recycle engine
fluids.
A Stop engine before maintaining.
IF See also Engine Manual and Maintenance Label.
Service engine more often if used in severe conditions.
@ sh
Wipe Up
Spills
ITA Check Fluid Levels,
See Section 3-6
Clean And
Tighten
Weld
Connections
Service
Air
Cleaner
Change
Oil.
Clean
Fuel
e” =
Sediment
S 5
Check
Spark
Plugs
Check
And Clean
Spark
Arrestor
Screen
O) 200h
Replace
==} Unreadable
Labels
e: Te Clean
Fuel Tank
And
Strainer
OM-484 Page 22
@) sooh
Check
Valve Repair Or Replace
Clearance ZA Cracked Cables
Blow Out Or Vacuum
Inside.
During Heavy Service,
Clean Monthly
AU ь
94 Imp gt)
Unleaded
86 + Octane
6.5¢(1.7 US Gal,
11.4 Imp pt)
07-08 mm
(0.028 — 0.031 in)
Ref, 5-175 679-A
OM-484 Page 23
6-3. Adjusting Engine Speed
" v After tuning engine, check
Er engine speeds (see table). If
necessary, adjust speeds as
follows:
Start engine and run until
warm.
Weld/Power Speed
«> | 1400+ 150 rpm Adjustment
1 Throttle Control Lever
© 3700 + 50 rpm 2 Adjustment Screw
Move lever to Run (60 Hz)
position. Turn screw and
move lever until engine runs
at weld/power speed.
Idle Speed Adjustment
3 Pilot Screw
4 Throttle Stop Screw
Move lever to idle position.
Turn pitot screw until engine
runs at highest idle speed,
Turn stop screw until engine
runs at rated idle speed {nor-
mally about 2-1/4 turns out.)
A Stop engine.
==
ST-801 269 / ST-801 273
OM-484 Page 24
6-4. Troubleshooting
= ‘ >.
A. Welding
Trouble Remedy
No weld output.
Check weld connections.
Disconnect equipment from receptacles when starting unit.
Reduce load and allow generator over-temp switch TP 1 to reset. TP1
opens and warning light goes on if generator overheats (see Section
4-1).
Check engine speed and adjust if necessary. Output stops and
warning light goes on if speed is too low (see Sections 4-1 and 6-3).
Have Factory Authorized Service Agent check brushes, slip rings,
circuit board PC1, capacitor C1, and rectifiers SR1 and SR2.
Low weld output.
Check Current Control R1 and throttle lever settings.
Check engine speed, and adjust if necessary (see Section 6-3).
Check weld cable size and length.
Service air cleaner according to engine manual.
Have Factory Authorized Service Agent check brushes, slip rings,
circuit board PC1, capacitor C1, and rectifiers SR1 and SR2.
High weld output.
Check Current Control R1 setting.
Check engine speed, and adjust if necessary (see Section 6-3).
Have Factory Authorized Service Agent check brushes, slip rings,
circuit board PC1, capacitor C1, rectifiers SR1 and SR2, and
suppressor VR1/R3.
Erratic weld output.
Check Current Control R1 setting.
Tighten and clean connections to electrode and workpiece.
Tighten and clean connections inside and ouiside welding generator.
Use dry, properly-stored electrodes for SMAW.
Remove excessive coils from weld cables.
Check engine speed, and adjust if necessary (see Section 6-3).
Check throttie/governor linkage for smooth, non-binding operation.
Have Factory Authorized Service Agent check brushes, slip rings,
circuit board PCH, capacitor C1, and rectifiers SR1 and SR2.
OM-484 Page 25
B. Auxiliary Power
Trouble
Remedy
No output at receptacles.
Reset circuit breakers.
Check connections to circuit board PC1.
Reduce load and allow generator over-temp switch TP1 to reset. TP1
opens and warning light goes on if generator overheats (see Section
4-1).
Check engine speed and adjust if necessary. Output stops and
warning light goes on if engine speed is too low {see Sections 4-1 and
6-3).
Check receptacie wiring and connections.
Have Factory Authorized Service Agent check brushes, slip rings,
circuit board PC1, capacitor C1, and rectifiers SR1 and SR2.
High power output.
Check engine speed, and adjust if necessary (see Section 6-3).
Move throttle lever to Run (50 Hz position for 50 Hz equipment).
Have Factory Authorized Service Agent check circuit board PC1 and
capacitor C1.
Low power output.
Move throttie lever to Run (60 Hz position for 60 Hz equipment).
Check engine speed, and adjust if necessary (see Section 6-3).
Erratic power output.
Check fuel level.
Check receptacle wiring and connections,
Check throttle/governor linkage for smooth, non-binding operation.
Service air cleaner according to engine manual.
Check engine speed, and adjust if necessary (see Section 6-3).
Have Factory Authorized Service Agent check brushes, slip rings,
and circuit board PC1.
C. Engine
Trouble
Remedy
Engine will not start.
Check fuel level. Open fuel valve.
Turn Engine Switch to On.
Set choke control correctly (see Section 3-6).
Check oil level and low oil level shutdown switch (see Section 3-6).
Engine suddenly stops.
Check fuel level. Open fuel valve.
Check oil level and low oil level shutdown switch (see Section 3-6).
Check unit operating angle. Low oil level shutdown switch may stop
engine if unit is tilted (see Section 3-4).
Unstable engine speeds.
Check engine speed, and adjust if necessary (see Section 6-3).
Check throttte/governor linkage for smooth, non-binding operation.
Check and clean spark arrestor.
Tune-up engine according to engine manual.
OM-484 Page 26
SECTION 7 —- ELECTRICAL DIAGRAM
6
— VÍ,
Go
Th
Da }
a o A A — Не o —— — — — — _ — ножен а аа а Е SE Es Es Es ss ss ss rss rs rs rss
[UK RECEPTACLE OPTON
— ——— — Ar ———— ны сн — кн Он Он Он с —
RC2
— y AAA A —_— — — — — = О кн кн = а
SOUTH AFRICAN RECEPTACLE OPTION
mn Amp AL mag A — — — — — pt. — 3
vv G ACI
| 230v
Fa"
`\ 5 RC2
230v
3
A A
—— E o TEr— кн Чате сны — не кн О = к =
RC2
230v
а YY,
— A
SOUTHEAST ASIA/BELGUM/THAILAND
RECEPTACLE OPTION
i IY Jo 5
|
|
|
|
|
|
| G
|
|
|
|
|
|
|
|
OM-484 Page 27
[ 20/240v OPTION W/TWIST Tock]
240V RECEPTACLE “y y y
я =— 1] —-I E Sh
B WG
ENGINE DIAGRAM
5 POSITIVE
O
À
- Pc
ho
vw
‚| О
МЕСАТМЕ
7 R43 Y T| F[T
>] da
vie 4 > | R44 4 o 2 Blé GENERATOR
EXCITER To | 45 7 N PC] ln! 4 ROSA Dra
DOS No «A N ® ® 0 9 2 RCS-2
S 25
: 15353 #9 19 #5 xl m
e eE 3 88 —
A AN A À A À AN A VER TEMP
2 PP ToR «en
© Su Bl Bl B
ENGRE 1-9
COL À (m) м ul \
CONTROL
et, lo
SC-174 790-D
OM-484 Page 28
SECTION 8 — PARTS LIST
Includes
items
18 & 19
ST-801 482-A
OM-484 Page 29
Item Dia Part
No. Mkgs No. Description Quantity
A +175614 ... COVER .......esreereeraaraa nina reee ene 1
‚Од s a 0005 175679 ... LABEL, warning general precautionary ........... 1
.3...SR2.., 175645 ... RECTIFIER, pos/neg (consisting of) .............. 1
Cera eae 176 426 ..... CHANNEL mtg rectifier ....................... 2
RAA 176 338 ..... TUBING, polyestgllam62 .................... 2
Cd 175681 ..... HEAT SINK, rectifier ,ı..0.0.00000000 2
CB 037305 ..... DIODE, rect 150A 300V SP ................... 2
A - 1..2200000. 037 306 ..... DIODE, rect +50A 300V RP ................... 2
Cea 176659 ..... CAPACITOR ...... 4
naar +175726 ... ENGINE ........... si e ere. 1
ere 182153 ... SPARKPLUG ............. ooo 1
Cees 182 157 ... ELEMENT, aircleaner .................... cou 1
Lea a aa en 0000 132 709 ,.. LABEL, wamingenginefuel ..................... 1
. 8...PCY1 ... 179437 ... CIRCUIT CARD, fieldcurrent .................... 1
Ces PLG5/RC5,
PLG4/RC4 168071 ... CONNECTOR & SOCKETS &PINS .............. 1
‚ 9 ........... 175 632 ... PANEL, rearleft ............... cc. iii, 1
10 .......... 175635 ... BRACKET migPC ............ cc. iii... 1
. 14 TET... 172661 ... BLOCK, connection6posn ...................... 1
12 VR1/A3 . 046819... SUPPRESSOR ............e..e0 AA 1
AB 11.220005 175613 ... BASE ......... 2 02e eee ea aa aa een ea ee sue 0» 1
Cae RC7 ... 168165... CONNECTOR & SOCKETS & PINS .............. 1
AA uan 1756727 ... GENERATOR, (consistingof) .................... 1
‚15 .......... 180877 ..... BRUSH EEE 1
‚16 .......... 180879 ..... BRUSH HOLDER ‚000000000000 sa a sea e 0 1
1 47 Las eee ee 180878 ..... BRUSH ARM ASSEMBLY ..................... 1
‚ 18 .......... 180 881 ..... (e 110]: UE 1
.19 ..SR1... 180880 ..... RECTIFIER, bridge . ....................... 00. 1
„20 .......... 176327 ... STUD, stl .312-24 x 10.750 ..................... 1
Tr 20000 013 367 ... LABEL, warning moving parts ................... 1
‚ 22 2......... 176202 ... SPACER, fan ............. кк. вк кк aa anne» 1
. 23 nara. 176 201 ... FAN ...........rereario.cerenerr nec near. 1
. 24 ..AC1... 007467 ... RECEPTACLE, twlk grd 2P3W 30A 125V ......... 1
.25 ..CB2 ... 093996 ... CIRCUIT BREAKER, man reset 1P 20A 250VAC . .. 1
.26 ..CBt ... 147658 ... CIRCUIT BREAKER, man reset 1P 30A 250VAC ... 1
C27 2121220000 175616 ... FRONT PANEL .......222 001020 e ae aa ea nana 0 1
. 28 .. HM ... 176365 ... HOURMETER ............... a aa aa ee ee een en» 1
.29 .. PL1 ... 082788... LIGHT HOLDER .....,.... 000000 eri. 1
.. 80 ..,....... *048 155... BULB .............e00rererirreei re rara ere. 1
31 Век... 176 246 ... LENS eae 1
BZ ee 129525 ... RECEPTACLE, twik fem (Dinse 50/70 series) ...... 2
EOS 145088 ... CONNECTIONKIT, Dinse ...................... 1
238 LL La ea aa aa sa sue 06 NAMEPLATE, (order by model and serial no.) ..... 1
BA en 073756 ... STAND-OFF, No. 6-32x .6251g .................. 2
.35 ..PC2... 148608 ... CIRCUIT CARD, HF filter ....................... 1
‚. 36 ........,. 097 924 ... KNOB WSCHEW ...0.0 ee» 1
. 37 ..RC2... 604176 ... RECEPTACLE, str dx grd 2P3W 15A 125V ........ 1
‚ 38 .. R1.... 035897 ... POTENTIOMETER, 1T 2W 1K .................. 1
aran PLG7 .. 130204 ... CONNECTOR & SOCKETS E PINS .............. 1
„39 2.00.0000 175620 ... BRACKET, mtg geM ....000000000r aa eee» 1
„40 ...Lt,... 175622 ... STABILIZER o.oo eee AD 1
#1 2.121200 +175 631 … PAN, bottom ............... cio iit. 1
2. 48 .......... 175633... PANEL, rearright ............... ccc, 1
. 43 ,. C1 . 176007 ... CAPACITOR, elctlt 1200uf 300VDC .............. 1
гованевьоннвннеу 176199 ... CAPACITORCLAMP .................. Y
AA LLL 028747 ... SHUNT, meter ........... iii, 1
‚ 45 2000000000 176 348 ... MOUNT, nprn ...12 00224400 ee ae aa ee ea eee 0e» 4
‚ 46 .......... 175615... BRACKET, enginemount ....................... 1
See following page for Optional Receptacle Kits
+When ordering a component originally displaying a label, the label should also be ordered.
*Recommended Spare Parts.
PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-484 Page 30
Optional Receptacle Kits
Dia Part
Mkgs No. Description Quantity
andrade 043 363... UK RECEPTACLE, (consisting of) .................. 1
CB1,2....147658..... CIRCUIT BREAKER, man reset 1P 30A 250VAC ... 2
CB3,4 .093995..... CIRCUIT BREAKER, man reset 1P 154 250VAC ... 2
RC1 ..... 173556 ..... RECEPTACLE, str2P3W32A130V ............... 1
RC2 ..... 173 555..... RECEPTACLE, str 2P3W 16A 130М ............... 1
eee 043 361... AUSTRALIAN RECEPTACLE, (consistingof) ........ 1
CB1-4 093995..... CIRCUIT BREAKER, man reset 1P 154 250VAC ... 4
RC1,2 171 352..... RECEPTACLE, str grd 2P3W 15A 250V ........... 2
Cae 043 360... SOUTH AMERICAN RECEPTACLE, (consisting of) ... 1
CB1,2 093995..... CIRCUIT BREAKER, man reset 1P 15A 250VAC ... 2
RC1,2 604 103 ..... RECEPTACLE, str dx grd 2P3W 15A 250V ......... 2
Cee a 043 364... SOUTH AFRICAN RECEPTACLE, (consisting of) ..... 1
CB1,2 093 995 ..... CIRCUIT BREAKER, man reset 1P 15A 250VAC ... 2
RC1,2 131 274..... RECEPTACLE, str grd 2P3W 16A 250V ........... 2
RAS 043359... SOUTH EAST ASIA RECEPTACLE, (consisting of) ... 1
CB1,2 093 995..... CIRCUIT BREAKER, man reset 1P 15A 250VAC ... 2
RC1,2 176 361..... RECEPTACLE, str grd 2P3W 16A250V ........... 2
RAA 043 362... EUROPEAN RECEPTACLE, (consistingof} .......... 1
CB1,2 093 995 ..... CIRCUIT BREAKER, man reset 1P 15A 250VAC ... 2
RC1,2 176 359..... RECEPTACLE, str grd 2P3W 16A 250V ........... 2
PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-484 Page 31
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement