Miller ROUGHNECK 207 CE Manuale del proprietario

Categoria
Sistema di saldatura
Tipo
Manuale del proprietario

Questo manuale è adatto anche per

Roughneck 207
Processes
Description
Stick (SMAW) Welding
Engine Driven Welding Generator
OM-197 878A February 2000
Effective with serial number: 162 489
Visit 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. To locate your nearest
distributor call 1-800-4-A-Miller.
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 Owners 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 parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Additional Symbols For Installation, Operation, And Maintenance 3. . . . .
1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – LABEL AND DEFINITIONS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Manufacturers Rating Label for CE Products 5. . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – SPECIFICATIONS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, and Engine Specifications 7. . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions and Weights 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Fuel Consumption 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Duty Cycle 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Auxiliary Power Curve 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Volt-Ampere Curve 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – INSTALLATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Grounding Generator to Truck or Trailer Frame 10. . . . . . . . . . . . . . . . . . . .
4-3. Grounding Generator When Supplying Building Systems 11. . . . . . . . . . . .
4-4. Engine Prestart Checks 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Connecting to Weld Output Terminals 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Selecting Weld Cable Sizes 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – OPERATING THE WELDING GENERATOR 13. . . . . . . . . . . . . . . .
5-1. Controls 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – OPERATING AUXILIARY EQUIPMENT 14. . . . . . . . . . . . . . . . . . . .
6-1. Using the AC Generator 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description of AC Generator 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Auxiliary Power Circuit Protection 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – MAINTENANCE 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Adjusting Engine Speed 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – TROUBLESHOOTING 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 – ELECTRICAL DIAGRAM 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 – AUXILIARY POWER GUIDELINES 22. . . . . . . . . . . . . . . . . . . . . .
SECTION 11 – STICK WELDING (SMAW) GUIDELINES 30. . . . . . . . . . . . . . . . .
SECTION 12 – PARTS LIST 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
OM-197 878A
dec_con1_italy11/02
Declaration of Conformity
CE Dichiarazione di Conformità
Manufacturers Name:
Nome del Costruttore:
ITW WELDING PRODUCTS ITALY S.r.l.
Manufacturers Address:
Indirizzo Costruttore:
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Declares that this product:
Dichiara che il Prodotto:
Roughneck 207
Conforms to the following Directives and Standards:
È Conforme alle seguenti Direttive e Norme.
Direttive
Machinery Directives: 89/392/EEC
Direttiva Macchine: 89/392/CEE
And their amendments 91/368/EEC, 93/C 133/04, 93/68/EEC
Aggiornate dalle direttive 91/368/CEE, 93/C 133/04, 93/68/CEE
Norme
To check the conformity the following harmonized norms have been consulted: EN–291–1, EN 292–2
Per la verifica sono state consultate le sequenti norme armonizzate:EN2911, EN 2922
European Contact: Mr. Danilo Fedolfi, Managing Director
In Europa Contattare: ITW WELDING PRODUCTS ITALY S.r.l.
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Telefono: 39(02)98290-1
Fax: 39(02)98290-203
OM-197 878 Page 1
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING
rom _nd_11/98
1-1. Symbol Usage
Means Warning! Watch 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 Warning! Watch Out! possible
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 1-5. Read and follow all
Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
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.
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).
Properly install and ground this equipment according to its
Owners Manual and national, state, and local codes.
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 conduc-
tor first double-check connections.
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced 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.
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.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters.
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
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.
ARC RAYS can burn eyes and skin.
Wear a welding helmet fitted with a proper shade of filter 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 and
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant mate-
rial (wool and leather) and foot protection.
Welding 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 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
manufacturers instructions 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 watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying op-
erations. 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-197 878 Page 2
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.
WELDING can cause fire or explo-
sion.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
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 closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
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.
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 oil-free protective garments 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.
FLYING METAL 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.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use ap-
proved air-supplied respirator.
HOT PARTS can cause severe burns.
Allow cooling period before maintaining.
Wear protective gloves and clothing when
working on a hot engine.
Do not touch hot engine parts or just-welded
parts bare-handed.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
MAGNETIC FIELDS can affect pacemak-
ers.
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
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.
CYLINDERS can explode if damaged.
Protect compressed gas cylinders from excessive heat, mechani-
cal 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 fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Engine Hazards
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.
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.
OM-197 878 Page 3
MOVING PARTS 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.
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.
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.
BATTERY 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 charge batteries or jump start vehicles.
Observe correct polarity (+ and ) on batteries.
Disconnect negative () cable first and connect it last.
BATTERY ACID can BURN SKIN and
EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE EXHAUST GASES can kill.
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.
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.
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.
1-4. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, trailer, or any other
accessories.
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.
FLYING SPARKS can cause injury.
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.
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.
OVERUSE can cause OVERHEAT-
ING.
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.
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.
TILTING OF TRAILER can cause injury.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
Use only genuine MILLER replacement parts.
Perform engine maintenance and service
according to this manual and the engine
manual.
OM-197 878 Page 4
H.F. RADIATION 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 prompt-
ly correct any interference problem resulting from the installa-
tion.
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.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
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 elec-
tronic 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.
1-5. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion 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
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-197 878 Page 5
SECTION 2 LABEL AND DEFINITIONS
2-1. Manufacturers Rating Label for CE Products
270020185
270010185
OM-197 878 Page 6
2-2. Symbol Definitions
Engine Choke
G
Engine-Driven,
Single-Phase
Alternator With
Rectifier
A
Amperes
V
Volts
Engine Oil Fuel Battery (Engine) Engine
Positive Negative
Alternating Current
(AC)
Output
h
Hours
s
Seconds Time
Protective Earth
(Ground)
Circuit Breaker Temperature
Read Operators
Manual
Direct Current
(DC)
OM-197 878 Page 7
SECTION 3 SPECIFICATIONS
3-1. Weld, Power, and Engine Specifications
Welding
Mode
Weld Output
Range
Rated
Welding
Output
Maximum
Open Circuit
Voltage
Auxiliary
Power
Rating
Fuel Capacity Engine
Acoustic
Power
Level*
2.5 kVA
110 CTE
22.7 A
20 170
170 A,
70
5 kVA
230 V
21.2 A
Honda 390
Air-Cooled,
One-Cylinder,
CC/DC
20 170
(50 Hz)
25 V
60% Duty Cycle
70
(50 Hz)
6.5 kVA
400 V
9.4 A
6.5 L tank
One-Cylinder,
Four-Cycle,
13 HP (390 CC),
Gasoline Engine
101 Lwa
5 kVA
230 V
21.7 A
* Maximum acoustic power level admitted according to the EEC norms of 17/09/84 number 84/535 for welding/generator sets.
3-2. Dimensions and Weights
Dimensions
Height 592 mm
Width 525 mm
Depth 870 mm
Weight
123 kg
without CTM-HM (11 Kg.) Option
OM-197 878 Page 8
3-3. Fuel Consumption
0 25 50 75 100 125 150 170
1234567
0
kVA
A
A
kVA
Continuous Welding
3-4. Duty Cycle
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
Exceeding duty cycle can
damage unit and void
warranty.
100% Duty Cycle at Amperes CC/DC
100
90
80
70
60
50
40
30
20
10
0
20 40 60 80 100 100 110 140 170
Welding Amperes
Duty Cycle
OM-197 878 Page 9
3-5. Auxiliary Power Curve
The ac auxiliary power curves
show the auxiliary power available
in amperes at the receptacles.
AC Volts
AC Power kVA
3-6. Volt-Ampere Curve
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
OM-197 878 Page 10
SECTION 4 INSTALLATION
4-1. Installing Welding Generator
1.5m
OR
Movement Airflow Clearance
Location
1.5m
1.5m
1.5m
1.5m
4-2. Grounding Generator to Truck or Trailer Frame
install1 1/97* Ref. ST-151 556 / S-0854
1 Generator Base
2 Metal Vehicle Frame
3 Equipment Grounding
Terminal
4 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
If unit does not have GFCI re-
ceptacles, use GFCI-
protected extension cord.
1
2
Electrically bond generator frame to
vehicle frame by metal-to-metal con-
tact.
GND/PE
3
4
2
OR
OM-197 878 Page 11
4-3. Grounding Generator When Supplying Building Systems
GND/PE
1 2
Use ground device as
stated in electrical codes.
2
3
ST-800 576-B
1 Equipment Grounding
Terminal
2 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3 Ground Device
Ground generator to sys-
tem earth ground if supply-
ing power to a premises
(home, shop, farm) wiring
system.
Check all fluids daily. Engine must
be cold and on a level surface.
Engine stops if oil level gets too low.
Follow run-in procedure in en-
gine manual.
1 Fuel Valve
Open valve.
Close fuel valve before moving
unit or carburetor may flood
and make starting difficult.
Fuel
Add fresh fuel before starting
engine the first time (see mainte-
nance label for specifications). Fill
fuel tank up to 1/2 in. (13 mm) from
top to allow room for expansion.
Check fuel level on a cold engine
before use each day.
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see main-
tenance label).
To improve cold weather
starting:
Keep battery in good condition.
Store battery in warm area off
concrete surface.
Use correct grade oil for cold
weather.
4-4. Engine Prestart Checks
Full
Full
Gasoline
1/2 in
(13 mm)
1
270000044
OM-197 878 Page 12
4-5. Connecting to Weld Output Terminals
1 Positive (+) Weld Output
Terminal
2 Negative () Weld Output
Terminal
For Direct Current Electrode Posi-
tive (DCEP), connect work cable to
Negative () terminal and electrode
holder to Positive (+) terminal.
For Direct Current Electrode nega-
tive (DCEN), reverse cable con-
nections.
1
270000022-1
2
4-6. Selecting Weld Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
Welding
Amperes
100 ft (30 m) Or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Amperes
10 60%
Duty Cycle
60 100% Duty
Cycle
10 100% Duty Cycle
100 16 16 16 25 35 50 50 50
150 25 25 35 50 50 70 3/0 95
200 25 35 50 50 70 95 4/0 120
250 35 50 50 70 95 120 2//70 2//70
Cable sizes are mm
2
. S-0007-E
OM-197 878 Page 13
SECTION 5 OPERATING THE WELDING GENERATOR
5-1. Controls
270000003-1
270000003-3
9 Welding socket ( + )
10 Welding socket ( )
12 Earth terminal
15 A.C. socket
22 Engine air filter
23 Oil level dipstick
26 Fuel tank cap
27 Muffler
31 Oil drain tap
59B Aux current circuit breaker
D Ground fault interrupter
(30 mA )
F Fuse
N Voltmeter
T Welding current regulator
W1 Remote control switch
X1 Remote control socket
OM-197 878 Page 14
SECTION 6 OPERATING AUXILIARY EQUIPMENT
6-1. Using the AC Generator
If unit does not have GFCI re-
ceptacles, use GFCI-protected
extension cord.
Auxiliary power decreases as
weld current increases.
Place throttle lever in Run position
(far left) for auxiliary power.
Circuit breakers protect the generator
from overload. Press button to reset
circuit breaker. If breaker continues to
open, contact Factory Authorized Ser-
vice Agent.
Combined output of all receptacles
limited to 6.5 kVA/kW (50 Hz) rating of
the generator.
270000022-3
OM-197 878 Page 15
6-2. Description of AC Generator
Make sure that the unit is properly
grounded.
The voltmeter shows the single-phase volt-
age whether three or single-phase current
needs to be drawn.
Actual voltage will be within +/10% of nom-
inal voltage.
Connect the equipment (using proper plugs
and cables that are in good condition) to the
AC socket to draw single or three-phase
power.
The green light, located near the AC socket,
lights up when the unit can supply AC power
providing that the engine is at the maximum
rpm.
If the green light does not light up, check
that the throttle is at maximum and that
the socket is ok.
If more than one socket is used at the same
time, the maximum continuous power is in-
dicated on the data plate. The maximum
continuous power of the generating set or
the maximum current must not be exceed-
ed.
Circuit Breaker
If the unit is overloaded the circuit breaker
trips automatically.
If the circuit breaker opens, disconnect all
the connected loads (see Figure 6.2.1).
Reset the circuit breaker by pressing the
central pole (see Figure 6.2.2).
When reset, reconnect the loads again.
Avoid holding the central pole of the
circuit breaker for an extended peri-
od of time or generator damage will
result.
Ground Fault Interrupter Circuit Breaker
Turn on the GFI safety-switch by pushing it
upwards (see Figure 6.2.3). The GFI is a
safety device which protects the operator. It
will only protect the operator if the welder is
properly grounded. The GFI cuts off the
three-phase and single-phase power if
there is a ground leakage of more than 30
mA.
270000022
Figure 6.2.1 Figure 6.2.2 Figure 6.2.3
OM-197 878 Page 16
6-3. Auxiliary Power Circuit Protection
2700000223
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Miller ROUGHNECK 207 CE Manuale del proprietario

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Manuale del proprietario
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