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Miller Electric 280 NT manual

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Table of contents for the manual

  • Page 1

    Miller Legend 302  Processes Description TIG (GT A W) W elding Stick (SMAW ) W elding MIG (GMAW) W elding & Flux Cored (FCA W ) W elding With V oltage Sensing Feeder Engine Driven Welding Generator OM-4430 217 243R 2007 − 04 File: Engine Drive V isit our website at www.MillerWelds.com[...]

  • Page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Routine Maintenance 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Maintenance Label 34 . . . . . . . [...]

  • Page 5

    OM-4430 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 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 [...]

  • Page 6

    OM-4430 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous.  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.  If ventilation is [...]

  • Page 7

    OM-4430 Page 3 1-3. Engine Hazards BA TTERY EXPLOSION can BLIND.  Always wear a face shield, rubber gloves, and protective clothing when working on a battery .  Stop engine before disconnecting or connect- ing battery cables or servicing battery .  Do not allow tools to cause sparks when working on a battery .  Do not use welder to char[...]

  • Page 8

    OM-4430 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion.  Do not cut or gouge near flammables.  W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury .  Do not touch hot compressor or air system parts.  Let system cool down before touching or ser- vicing. READ INSTRUCTIONS.  [...]

  • Page 9

    OM-4430 Page 5 H. F . RADIA TION can cause interference.  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 corre[...]

  • Page 10

    OM-4430 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des ble[...]

  • Page 11

    OM-4430 Page 7 Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation.  Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.  Ne pas to[...]

  • Page 12

    OM-4430 Page 8  Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et N FPA 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 affe c l’ouïe.  Porter des protections approuvés pour les or e les si le niveau sonore [...]

  • Page 13

    OM-4430 Page 9  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.  Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore.  JAMAIS utiliser dan[...]

  • Page 14

    OM-4430 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant d e démarrer ou d’ a rrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager l e moteur électrique à cause d’une tension et d’une fré - quence trop faibles.  N e pas[...]

  • Page 15

    OM-4430 Page 1 1 2-6. P r oposition californienne 65 A ver tissements 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 mal- formations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de[...]

  • Page 16

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 12 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Panel/Local T emperature Fuel Engine Oil Engine Choke Check V alve Clearance Battery (Engine) Engine Read Operator’s Manual A Amperes V [...]

  • Page 17

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 13 SECTION 4 − SPECIFICA TIONS 4-1. Description This multiprocess engine-driven welder and AC generator provides low speed generator AC power and D C w eld o ut- put for quiet, fuel-ef ficient operation. At 1800 rpm, this unit produces 5 kW/kV A 60 Hz 120/240 V olt AC ge[...]

  • Page 18

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 14 4-4. Dimensions For Units With Optional Running Gear Dimensions Height All Running Gear Options: 42-1/2 in (1079 mm) (T o T op Of Handle Assembly) C A Protective Cage Width: 26 in (660 mm) D C B Running Gear Width: 32 in (813 mm) C Protective Cage Length: 48 in (1219 mm[...]

  • Page 19

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 15 222 553 The ac generator power curve shows the generator power avail- able in amperes at the receptacles. 4-6. Generator Power Curve AC AMPERES AC VOL TS 0 5 10 15 20 25 30 0 50 100 150 200 250 300 Notes BUTT BUTT BUTT BUTT T − JOINT T − JOINT T − JOINT T − JOIN[...]

  • Page 20

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 16 Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle ca n damage unit and void warranty . 100% Duty Cycle at 280 Amperes DC/CC Continuous Welding 4-7. Duty Cycle Ref. 207 925 01 0 20 30 40 50 60[...]

  • Page 21

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 17 222 555 / 222 556 / 222 557 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding generator . Curves of other settings fall between the curves shown. A. CC/DC Stick Mode B. CV/DC MIG Mode 4-9. Stick And MIG Mode V o[...]

  • Page 22

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 18 SECTION 5 − INST ALLA TION install2 12/06 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712 ! Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. ! Always securely fasten weld- ing generator on[...]

  • Page 23

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 19 5-2. Engine Prestart Checks 803 983 − A / Ref 216 172-D Full Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil.  Follow run-in procedure in engine manual.  This unit has a low oil pressure shutdown switch.[...]

  • Page 24

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 20 5-3. Connecting Or Replacing The Battery + − ! Connect negative ( − ) cable last. 803 847 / 803 849 / Ref. S-0756-D Ref 216 172-D / Ref 803 983 − A 3/8, 1/2 in T ools Needed: Replacing The Battery + − + −  Remove end panel to replace battery . ! Connect neg[...]

  • Page 25

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 21 5-4. Installing Exhaust Pipe Ref 216 172-D / 803 891 ! Stop engine and let cool. ! Engine backfire can cause se- vere burns or other injuries. Do not point exhaust pipe to- ward control panel. Keep away from exhaust outlet. ! Point exhaust pipe in desired direction but [...]

  • Page 26

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 22 5-5. Connecting T o Weld Output T erminals ! Stop engine. ! Do not connect to CC and CV terminals at the same time. 1 Negative ( − ) W eld Output T erminal 2 Stick/TIG (CC) W eld Output T erminal 3 Wire /CV W eld Output T erminal Fo r MIG welding, connect work cable t[...]

  • Page 27

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 23 5-6. Selecting W eld Cable Sizes* W eld Output T erminals ! W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** ! Stop engine before connecting to weld output terminals. ! Do not use worn, damaged, under- sized, or poorly spliced cables.[...]

  • Page 28

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 24 SECTION 6 − OPERA TING WELDING GENERA TOR 6-1. Front Panel Controls 2 1 4 3 Ref 216 172-D 7 5 6 8 9 1 Process Switch Se e Section 6-5 for Process switch informa- tion. 2 Remote Receptacle Use receptacle to connect remote control. When a remote voltage/amperage control[...]

  • Page 29

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 25 6-2. Description Of Engine Controls (See Section 6-1 ) Engine Control Switch Us e switch to start engine, select speed, and stop engine. Use switch in combination with Engine Speed Control switch to select en- gine speed. In Run/Idle 3600/2400 RPM position, engine runs [...]

  • Page 30

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 26 6-4. Controlling Engine Speed And W eld/Generator Output Ref 216 172-D  Set engine controls as shown to obtain the corresponding weld and generator power out- put. NOTICE − Disconnect equipment from auxiliary power receptacles during start-up and shutdown. Some equ[...]

  • Page 31

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 27 1 Process Switch ! Weld output terminals are energized when Process switch is in an Elec- trode Hot position and the engine is running.  The unit will not return to idle speed when Process switch is in a Wire or TIG position and the remote contactor is on (closure be[...]

  • Page 32

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 28 6-6. Stick Start Procedure − Scratch Start T echnique With Stick selected, start arc as follows: 1 Electrode 2 W orkpiece 3 Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to [...]

  • Page 33

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 29 6-8. Remote V oltage/Amperage Control 1 Remote Receptacle RC4 Connect optional remote voltage/ amperage (V/A) control to RC4 (see Section 5-7). With remote control connected, weld output in a CC mode (Stick, TIG) is determined by a combination of front panel and remote [...]

  • Page 34

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 30 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. 60 Hz Generator Power Receptacles And Supplementary Protectors Ref. 21 1 909 ! If unit does not have GFCI re- ceptacles, use GFCI-protected extension cord. NOTICE − Disconnect equipment from auxiliary power receptacle[...]

  • Page 35

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 31 Ref. 216 172-D 7-2. V ariable Frequency (Hz) Generator Power Receptacle RC3 NOTICE − Do not operate equipment requiring a constant frequency from variable frequency receptacle RC3. 1 120 V 20 A V ariable Frequency AC Receptacle RC3 Receptacle supplies single-phase pow[...]

  • Page 36

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 32 7-3. Wiring Instructions For Optional 240 V olt, Single-Phase Plug (NEMA 14-50P) plug1 1 1/03 − 120 813-D The plug can be wired for a 240 V , 2-wire load or a 120/240V , 3-wire load. See circuit diagram. 1 Plug Wired for 120/240 V , 3-Wire Load When wired for 120 V lo[...]

  • Page 37

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 33 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance  Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. ! Stop engine before maintaining.  S ee Engine Manual and Maintenance Label f[...]

  • Page 38

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 34 8-2. Maintenance Label  Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.[...]

  • Page 39

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 35 ! Stop engine and let cool. 1 Spark Arrestor Screen Clean and inspect screen. Replace spark arrestor if screen wires are broken or missing. 8-3. Servicing Optional Spark Arrestor 1/4 in 803 983 − A / Ref 216 172-D T ools Needed: 1 8-4. Servicing Air Cleaner aircleaner[...]

  • Page 40

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 36 8-5. Changing Engine Oil, Oil Filter , And Fuel Filter 803 983 − A / Ref 216 172-D / S-0842 ! Stop engine and let cool. 1 Oil Drain V alve 2 Oil Filter Change engine oil and filter accord- ing to engine manual. NOTICE − Close valve and valve cap before adding oil an[...]

  • Page 41

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 37 ! Stop engine. Open left side door .  When a supplementary protec- tor or fuse opens, it usually indi- cates a more serious problem exists. Contact a Factory Au- thorized Service Agent. 1 Supplementary Protector CB4 CB4 protects the stator winding supplying 24 volt a[...]

  • Page 42

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 38 8-7. T roubleshooting A. Welding T rouble Remedy No weld output. Check weld control settings. Check weld connections. Disconnect equipment from generator power receptacles during start-up. Increase front panel and/or remote control voltage/amperage control setting (see [...]

  • Page 43

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 39 T rouble Remedy Lack of high frequency; difficulty in establishing Gas Tungsten Arc W el d - ing arc. Use proper size tungsten for welding amperage. Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive coils from weld cables, use [...]

  • Page 44

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 40 D. Engine T rouble Remedy Engine will not crank. Check fuse F6, and replace if open (see Section 8-6). Check battery voltage. Check battery connections and tighten if necessary . Check plug PLG5 and plug PLG8 connections. Have Factory Authorized Service Agent check Engi[...]

  • Page 45

     A complete Parts List is available at www .MillerW elds.com OM-4430 Page 41 SECTION 9 − P ARTS LIST 9-1. Recommended Spare Parts Description Part No. Dia. Mkgs. Recommended Spare Parts Quantity F6 021718 Fuse, Mintr Gl 30. Amp 32 V olt 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 46

    OM-4430 Page 42 SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welding Generator Models[...]

  • Page 47

    OM-4430 Page 43 232 961-A[...]

  • Page 48

    OM-4430 Page 44 SECTION 1 1 − GENERA TOR POWER GUIDELINES  The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 1 1-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST -159 730 / ST -800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-[...]

  • Page 49

    OM-4430 Page 45 1 1-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device  Us e ground device as stated in electrical codes. ! Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system[...]

  • Page 50

    OM-4430 Page 46 1 1-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starti ng W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 28[...]

  • Page 51

    OM-4430 Page 47 1 1-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in [...]

  • Page 52

    OM-4430 Page 48 1 1-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not l[...]

  • Page 53

    OM-4430 Page 49 1 1-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices. ! Properly install and ground this [...]

  • Page 54

    OM-4430 Page 50 1 1-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 840 [...]

  • Page 55

    OM-4430 Page 51 Notes SOCKET/WRENCH SELECTION T ABLE (U.S. ST ANDARD) SOCKET/WRENCH SELECTION T ABLE (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size Bolt Diameter Decimal Equivalent Bolt Nut Bolt Diameter U.S. Decimal Equivalent Bolt Nut 1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm 5/16 in .3125 in 1/2 [...]

  • Page 56

    OM-4430 Page 52 Notes Welding Symbols Ref. AWS/ANSI A2.4[...]

  • Page 57

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  • Page 59

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y ou r distributor also gives you ... Service Y ou 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 exp[...]

  • Page 60

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W or ks Comp any 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarte rs − USA USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX : 920-735-4134 Int ernati onal F A X: 9 20-735-4125 European Headqua rters ?[...]