Miller Electric Metro 250D manual

Processes OM-402B April 1997 Eff. w/Serial Number KH383240 Gas Tungsten Arc (TIG) W elding Shielded Metal Arc (Stick) W elding Flux Cored Arc W elding Description Engine Driven Welding Generator  With Optional Equipment: Metro 250D V isit our website at www.MillerWelds.com[...]

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

Descripti on Feat ure s  NEW! W arranty extended to 3 years (engine warranted by engine manufacturer)  V ersatile weld output for DC Stick and DC TIG welding  Stepless amperage control for precise heat selection  Arc force control ensures a forceful arc for tight fit-ups − prevents electrode sticking  Built-in Hot Start circuit for[...]

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1 OM-402 1 . Safety Precauti ons − Read Before Using 1.1 Symbol Usage OM-402B -4/97, safety_rom 4/97 Means Warning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special safety message.  Means “Note”; not safety related. This group of symbols means W arning![...]

2 OM-402 W elding on closed containers, such as tanks, drums, o r pipes, can cause them to blow up. Sparks c a n 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 i[...]

3 OM-402 MOVING P ARTS can cause injury .  Keep away from 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 people remove guards or covers for maint- enance and troubleshooting as necessary .  T o prevent accidenta[...]

4 OM-402 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.  Th e user is responsible for having a qualified electrician prompt- ly correct [...]

5 OM-402 1 . C onsi gn es de sécurité − l ire a vant u t ilisation 1.1 Signification des symboles OM-402B - 4/97, safety_rom_fre 4/97 Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.  Identifie un message de sécurité particulier [...]

6 OM-402 Le soudage ef fectué 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 acciden[...]

7 OM-402 DES ORGANES MOBILES peuvent provoquer des blessures.  Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement.  Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.  Arrêter le moteur avant d’installer ou brancher l’appareil.  Demander seul[...]

8 OM-402 LES CHARGES ÉLECTROSTA TIQUES peuvent endommager les circuits imprimés.  Établir l a 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 entraîner [...]

9 OM-402 2 . Defini tions 2.1 Symbols and Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Glow Plug T emperature Fuel Engine Oil 14 Remote 14 Panel/Local On Check Injectors/ Pump Check V alve Clearance Battery (Engine) V V olts A Amperes Stick (SMAW) Arc Force (DIG) TIG (GTA W ) G Engine-Driven, Single-[...]

10 OM-402 3/96 2.2 General Precautionary Label 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 S-176 105-A + 2 2.1 2.2 + 5 + 7 7.1 7.2 2.3 + 6 6.1 6.2 6.3 + = A. W arning! Watch Out! There are possible hazards as shown by the symbols. B. Become trained and read the instructions before working on the machine or welding. 1 Electric shock from welding electrode or [...]

11 OM-402 2.3 Battery Charging Label 3/96 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Do not smoke and keep matches and flames away from battery . 3 Sparks can cause battery gases to explode. Battery explosion can blind and injure. W ear a face shield. 4 Battery acid can burn skin. Do not spill acid. 5 Read Owner ?[...]

12 OM-402 2.5 Hot Muffler Label 3/96 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Hot muf fler and exhaust pipes can cause severe burns. Do not touch hot muf fler or pipes. 1 S-176 230 2 2.6 Diesel Fuel Label 3/96 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Engine fuel plus flames o[...]

13 OM-402 2.7 Falling Equipment Label S-176 104 3/96 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Falling equipment can cause serious injury and damage. 3 Use lifting eye to lift or move unit only . Use proper equipment when lifting. 4 Do not use lifting eye to lift and support unit and trailer or other heavy device[...]

14 OM-402 2.9 Do Not Use Ether Label 3/96 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Ether will damage engine. Do not use ether as a starting aid. 3 Read Owner ’ s Manual. 4 Use glow plugs for 10 − 25 seconds to aid starting in cold weather . 1 S-176 109 10 − 25 s 2 3 4 2.10 Manufacturer ’ s Rating Label S[...]

15 OM-402 3 . Specifi cations 3.1 W eld, Power , and Engine Specifications Rated W elding Output Amperage Range Maximum Open-Circuit V oltage DC Auxiliary Power Rating Engine Fuel Capacity A verage Sound Level 280 A, 31 V DC, 60% Duty Cycle 250 A, 30 V DC, 100% Duty Cycle 20 − 280 61 (A verage) Single-Phase, 10 kV A/kW , 42 A, 120/240 V , 60 Hz D[...]

16 OM-402 3.4 Fuel Consumption SA-180 263-A 3.5 Duty Cycle and Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.  Exceeding duty cycle can damage unit and void warranty . duty1 5/95 / SB-180 262 4 Minutes W elding 6 Minutes Resting 100% Duty Cycle At 250 Amperes 6 Minutes W elding 4 Minute[...]

17 OM-402 3.6 AC Auxiliary Power Curve SA-180 260 The auxiliary power curve shows the auxiliary power in amperes available at the receptacles. 4 . Installation 4.1 Installing W elding Generator install1 1/97 − Ref. ST-800 652 / Ref. ST -800 477-A / ST -158 936-A / S-0854 1 Generator Base 2 Metal V ehicle Frame 3 Equipment Grounding T erminal 4 Gr[...]

18 OM-402 4.2 Connecting Battery and Installing Exhaust Pipe ST-801 079-A / Ref. ST -175 918-C 7/16, 1/2 in + −  Connect negative ( − ) cable last. T ools Needed:  Stop engine.  Installation of exhaust pipe is optional. 4.3 Engine Prestart Checks Ref. ST-159 219-D Check all fluids daily . Unit must be cold an d o n a l e v e l s u r fa[...]

19 OM-402 4.4 Connecting to Weld Output T erminals Ref. ST-158 936-D / Ref. ST -175 918-C 1 Positive (+) W eld Output T erminal 2 Negative ( − ) W eld Output T erminal For Direct Current Electrode Positi- ve (DCEP), connect work cable to Negative ( − ) terminal and electrode cable (Stick) or torch cable (TIG) t o Positive (+) terminal. Fo r Dir[...]

20 OM-402 4.6 Remote 14 Receptacle RC1 Information Ref. S T -158 9 3 Socket* Socket Information A 24 volt ac with respect to socket G. Protected by circuit breaker CB5. B Contact closure to A completes 24 volt ac contactor control circuit. AJ B K I G Circuit common for 24 volt ac circuit. B K I C L NH D M G F C 0 to +10 volts dc output to remote co[...]

21 OM-402 5 . Op eratin g th e Weld ing Generator 5.1 Front Panel Controls Ref. ST-175 918-C 9  Heavy loading during first 50 hours will damage engine. Keep load less than 225A (weld) or 7 k V A (power) for first 5 0 hours. 1 Engine Control Switch Use switch to operate glow plug (optional − see table), start engine, select speed, and stop engi[...]

22 OM-402 5.2 Remote Amperage and Contactor Control  W eld output terminals are energized when Output (Contactor) Control switch is On and engine is running. 1 Remote 14 Receptacle RC1 Connect optional remote control to RC1 (see Section 4.6).  Place Engine Control switch in Run position for HF-start TIG welding. Ref. ST-158 936-D / Ref. ST -1[...]

23 OM-402 6 . Oper ating Auxiliary Equipment 6.1 Auxiliary Power Receptacles  Place Engine Control switch in Run position to maintain weld/power speed under light auxiliary power loads.  Press button to reset circuit breaker . If a circuit breaker continues to open, contact a Factory Authorized Service Agent. 1 120 V 15 A AC Duplex Receptacle[...]

24 OM-402 7 . Mainte nance & Troubleshoot ing 7.1 Routine Maintenance Recycle engine fluids.  Stop engine before maintaining.  Se e also Engine Manual and Maintenance Label. Service engine more often if used in severe conditions. 8 h Wipe up spills. Check fluid levels. See Section 4.3. 50 h Clean and tighten weld connections. Clean air fi[...]

25 OM-402 6-2. Maintenance Label S-157 812-E 20W 30 50 40 API CD-MIL L 2104D, SF/CD, CC/CD 2.4 qt (2.3 L) MILLER 066 702 Deutz 77-175-24 MILLER 066 1 1 3 1 1.8 gal (44.6 l ) 100 Hrs. + 12 V BCI 58 430 A @ 0 ° F (-18 ° C) Deutz 77-656-19 72 ° F (20 ° C) 0.006 in (0.15 mm) Deutz 77-644-39 DIESEL DIN 51 601 BS 2869: A1, A2 ASTM D 975-81: 1-D, 2-D [...]

26 OM-402 7.3 Changing Engine Oil and Oil Filter Ref. ST-159 219-D / Ref. ST -159 215-E / Ref. ST -175 918-C / Ref. S-0842 T ools Needed:  Stop engine. See engine manual for oil/filter change procedure. Drain oil while engine is warm. 1 Oil Fill Caps (Use Either Cap) 2 Oil Drain V alve  Close oil drain valve and cap before adding oil and runn[...]

27 OM-402 7.4 Changing Fuel Filters  Stop engine and let cool. 1 Secondary Fuel Filter Remove filter . Apply thin film of oil to gasket on new filter . Install filter . 2 Primary Fuel Filter 3 Fuel Line Remove filter . Inspect all fuel lines and replace if cracked or worn. Install new filter and clamps. Wipe up any spilled fuel. Start engine, an[...]

28 OM-402 7.6 Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer (see table for no load speeds). If necessary , adjust speeds as follows: Start engine and run until warm. Idle Speed Adjustment T urn Engine Control switch to Run/ Idle position. 1 Idle Speed Lock Nut 2 Idle Speed Screw Loosen nut. Turn screw until engin[...]

29 OM-402 7.7 Overload Protection  Stop engine. If checking fuse, disconnect battery negative ( − ) cable.  Press button to reset circuit breaker . If fuse or breaker continues to open, contact Factory Authorized Service Agent. W eld And Auxiliary Power Circuits 1 Fuse F2 F2 protects battery excitation circuit. If F 2 opens, weld and auxil-[...]

30 OM-402 7.8 Servicing Optional Spark Arrestor ST-801 154-B / Ref. ST -175 918-C  Stop engine and let cool. 1 Spark Arrestor 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 fir[...]

31 OM-402 T rouble Remedy Erratic weld output. Clean and tighten weld output connections inside and outside unit. Use dry , properly-stored electrodes. Remove excessive coils from weld cables. Be sure connection to work piece is clean and tight. Have Factory Authorized Service Agent check brushes, slip rings, main rectifier , integrated rectifier S[...]

32 OM-402 T rouble Remedy Engine cranks but does not start. Check fuel level (see Section 4.3). Reset circuit breaker CB6 (see Section 7.7). If equipped with glow plug (optional), reset circuit breaker CB9 (see Section 7.7). Check Engine Control switch S1, and replace if necessary . Check low oil pressure shutdown switch S2, and replace if necessar[...]

33 OM-402 Notes[...]

34 OM-402 8 . Electrical Diagram 8.1 Circuit Diagram for Welding Generator[...]

35 OM-402 SC-181 758[...]

36 OM-402 9. Run-In Pr ocedur e 9.1 W etstacking runin2 12/96  Heavy loading during first 5 0 hours will damage engine. Keep load less than 225A (weld) or 7 kV A (power) for first 5 0 hours.  Do not idle engine longer than necessary . Piston rings seat faster if engine runs at weld/ power rpm, and the welding generator is kept loaded during r[...]

37 OM-402 9.2 Run-In Procedure Using Load Bank S-0683  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables. 1 Load Bank T urn all load bank switches Of f. If needed, connect load bank to 1 15 volts ac wall receptacle or genera- tor auxiliary power receptacle. 2 Welding G[...]

38 OM-402 9.3 Run-In Procedure Using Resistance Grid S-0684  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/ grid.  Keep exhaust and pipe away from flammables. 1 Resistance Grid Use grid sized for generator rated output. Turn Off grid. 2 Welding Generator Set Amperage control at min. 3 W eld Cables Connect grid to [...]

39 OM-402 10 . Auxiliary Power Guidelines 10.1 Selecting Equipment aux_pwr 12/96 − Ref. ST-159 730 / ST -800 577 1 Auxiliary Power Receptacles − Neutral Bonded T o Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated Equipment OR 2 Be sure equipment has this symbol and/or wording. 3 1 10.2 Grounding Generator t[...]

40 OM-402 10.3 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  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in electrical code[...]

41 OM-402 10.5 Approximate Power Requirements for Industrial Motors Industrial Motors Rating Sta rtin g 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 2850 3 HP[...]

42 OM-402 10.7 Approximate Power Requirements for Contractor Equipment Contractor Rating Starting W atts 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 3900 14[...]

43 OM-402 10.8 Power Required to Start Motor 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 listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting amper- ag[...]

44 OM-402 10.10 T ypical Connections to Supply Standby Power S-0405-A 1 Power Company Service Meter 2 Main and Branch Overcurrent Protection 3 Double-Pole, Double-Throw T ransfer Switch Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection. 4 Circuit Breakers or Fused Disconnect Switch Ob[...]

45 OM-402 10.1 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) 7 840 400 [...]

46 OM-402 1 1. P a r t s L i s t 1 1.1 Main Assembly 1 2 3 4 5 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 84 85 86 87 88 89 90 91 92 93 96 94 6 7 Fig 1 1 -2 Fig 1 1 -4 95 83  Hardware is common and not available unless listed.[...]

47 OM-402 30 ST-801 488-A 31 32 33 34 35 36 37 38 39 40 43 45 47 48 49 50 51 52 53 54 56 Fig 1 1 -3 57 58 59 60 62 63 65 66 67 68 69 70 71 72 73 74 75 76 77 78 80 79 81 61 82 42 64 55 41 44 46[...]

48 OM-402 1 1.1 (Continued) Description Part No. Dia. Mkgs. Item No. Quantity 1 +163 828 P ANEL, side LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 164 507 P ANEL, side LH rear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

49 OM-402 1 1.1 (Continued) Description Part No. Dia. Mkgs. Item No. Quantity 41 173 931 PIPE, exhaust elbow 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 167 313 LA TCH, elastic draw 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

50 OM-402 1 1.1 (Continued) Description Part No. Dia. Mkgs. Item No. Quantity 88 162 515 RECTIFIER, si diode (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1,3 048 420 CAP ACITOR, cer disc .01uf 1000VDC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

51 OM-402 1 1.2 (Continued) ST-801 515-A 1 2 3 4 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28  Hardware is common and not available unless listed. Description Part No. Dia. Mkgs. Item No. Quantity 13 CB5 083 432 CIRCUIT BREAKER, man reset 1P 10A 250V AC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 [...]

52 OM-402 1 1.3 Generator (Fig 1 1.1 Item 56) 1 ST-801 289A 2 4 5 3 6 7 8 9 10 11 16 15 14 13 12  Hardware is common and not available unless listed. Description Part No. Item No. Quantity 1 166 770 STUD, stl .375-16 x 19.750 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 160 943[...]

53 OM-402 ST-801 288 1 2 3 4 4 5 6 7 8 9 10 11 12 13 8 14 15 16 1 1.4 Control Box w/Components (Fig 1 1.1 Item 86)  Hardware is common and not available unless listed. Description Part No. Dia. Mkgs. Item No. Quantity 1 D1,5 135 184 DIODE BOARD 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

54 OM-402 Notes[...]

Notes[...]

56 OM-402 Notes[...]

Notes[...]

58 OM-303 12 . Options and Accessories 12.1 Metro 250D WELD METERS − DC AMP & VOL T (#042 947 Field ) Machine is prewired for easy installation of field kit. ST ARTING AID KITS (#043 139 Field ) Improve starting in cold weather by adding air intake manifold glow plug. Machine is prewired. SP ARK ARRESTOR (#042 915) May be mandatory in some ar[...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y our 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 expertise o[...]

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Compa ny 1635 West S pencer Street Applet on, WI 54914 USA International He adquarte rs − US A USA Phone: 920-735-4505 Auto-At t ended USA & Canada F A X: 9 20-735-4134 Int ernati onal F AX: 9 20-735-4125 European Headqua rters − United [...]