Miller AIR PAK Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

cover 5/94 ST-121 575-B PRINTED IN USA
1995 MILLER Electric Mfg. Co.
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
Give this manual to the operator.
For help, call your distributor
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912 414-734-9821
OWNER’S
MANUAL
May 1995 Form: OM-478J
Effective With Serial No. KF824571
CC/CV AC/DC Welding Generator
For SMAW, GMAW, FCAW, GTAW Welding And CAC-A
400 Amperes, 36 Volts DC At 100% Duty Cycle
10 Or 15 kVA/kW AC Auxiliary Power Plant With Overload Protection
3 kVA/kW AC Auxiliary Power With Overload Protection
Deutz F4L912, Air-Cooled, Diesel Engine
Battery Charge/Jump Start Option Available
For Options And Accessories, See Rear Cover
Miller Air Pak
miller_war1 6/95
MILLER’S TRUE BLUE LIMITED WARRANTY
Effective January 1, 1995
(Equipment with a serial number preface of “KD” or newer)
This limited warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY Subject to the terms and conditions below, MILLER Electric
Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new
MILLER equipment sold after the effective date of this limited warranty is free of de-
fects in material and workmanship at the time it is shipped by MILLER. THIS WAR-
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT-
NESS.
Within the warranty periods listed below, MILLER will repair or replace any war-
ranted 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 retail purchaser, or
one year after the equipment is sent to a North American distributor or eighteen
months after the equipment is sent to an International distributor.
1. 5 Years Parts 3 Years Labor
* Original main power rectifiers
* Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Supplies
* Intellitig
* Robots
3. 2 Years — Parts and Labor
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manufacturer.)
* Air Compressors
4. 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
* Running Gear/Trailers
* Plasma Cutting Torches (except APT, ZIPCUT & PLAZCUT Models)
* Tecumseh Engines
* 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.)
5. 6 Months — Batteries
6. 90 Days — Parts and Labor
* MIG Guns/TIG Torches
* APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches
* Remote Controls
* Accessory Kits
* Replacement Parts
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 fail due to normal wear.
3. Equipment that has been modified by any party other than MILLER, or equip-
ment 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 COMMER-
CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the exclusive remedies
shall be, at MILLER’S option: (1) repair; or (2) replacement; or, where authorized in
writing by MILLER in appropriate cases, (3) the reasonable cost of repair or replace-
ment at an authorized MILLER service station; or (4) payment of or credit for the pur-
chase price (less reasonable depreciation based upon actual use) upon return of the
goods at customer’s risk and expense. MILLER’S option of repair or replacement
will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a MILLER authorized ser-
vice facility as determined by MILLER. Therefore no compensation or reimburse-
ment for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON-
TRACT, TORT OR ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR-
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN-
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an implied warranty
lasts, or the exclusion of incidental, indirect, special or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty provides spe-
cific 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 I CONTACT?
For help,
H contact your distributor
For additional information, such as
Technical Manuals (Service And Parts)
Engine Manuals
Circuit And Wiring Diagrams
Process Handbooks
User’s Guides
Distributor Directories
H contact your distributor
To file a claim for loss or damage during
shipment,
H contact the delivering carrier
For assistance in filing or settling claims,
H contact your distributor and/or equipment
manufacturer’s Transportation
Department
Miller Electric Mfg. Co.
H CALL:
414-735-4505
H FAX:
800-637-2348 (in USA), or
414-735-4136 (outside USA)
H WRITE:
Miller Electric Mfg. Co.
P.O. Box 1079
Appleton, WI 54912 USA
Always provide Model Name and Serial or Style Number
OM-478J 5/95
EMF INFORMATION
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:
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 the body.
4. Keep welding power source and cables as far away as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
NOTE
mod10.1 4/93
TABLE OF CONTENTS
SECTION 1 SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Duty Cycle 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Fuel Consumption 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Volt-Ampere Curves 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. AC Auxiliary Power Curves 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Air Compressor Output Curve 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Selecting A Location And Moving Welding Generator 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Installing Precleaners, Exhaust Pipe, And Rain Cap 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Connecting The Battery 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Engine Prestart Checks 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Grounding The Generator Auxiliary Power System And Lower Panel Components 8. . . . . .
3-6. Selecting And Preparing Weld Output Cables 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Connecting To Weld Output Terminals 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Remote 14 Receptacle Or Terminal Strip Connections 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Air Compressor Connections 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Installing Ether Cylinder (Optional Ether Starting Aid) 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 OPERATING THE WELDING GENERATOR 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 OPERATING AUXILIARY EQUIPMENT 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Auxiliary Power Receptacles And Circuit Breakers 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Connecting To Auxiliary Power Plant 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 OPERATING OPTIONAL BATTERY CHARGER 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 MAINTENANCE & TROUBLESHOOTING 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Maintenance Lights And Air Tank Drain Control 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Oil And Fuel System Components 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Servicing Air Cleaner 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Adjusting Engine Speed 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Adjusting Air Pressure 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Overload Protection 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Replacing Battery Or Checking Battery Voltage 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9. Checking And Replacing Engine Belt 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-10. Optional Spark Arrestor Inspection And Cleaning 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-11. Troubleshooting 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 ELECTRICAL DIAGRAMS 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 RUN-IN PROCEDURE 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Run-In Procedure Using Load Bank 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Run-In Procedure Using Resistance Grid 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 AIR COMPRESSOR TABLES 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 AUXILIARY POWER GUIDELINES 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. How Much Power Does Equipment Require? 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. How Much Power Can Generator Supply? 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3. Typical Connections To Supply Standby Power 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4. Selecting Extension Cord 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 TUNGSTEN ELECTRODE 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1. Selecting Tungsten Electrode 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2. Preparing Tungsten 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 PARTS LIST 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-1A. Main Assembly (Part 1) 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-1B. Main Assembly (Part 2 of 2) 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-2. Panel, Front w/Components 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-3. Panel, Front Lower w/Components 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-4. Control Box 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-5. Compressor, Air 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-6. Generator 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-478 Page 1
SECTION 1 SAFETY INFORMATION
mod1.1 2/93
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1 Safety Alert Symbol
2 Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION means possible minor
injury or equipment damage can
happen.
3 Statement Of Hazard And
Result
4 Safety Instructions To Avoid
Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
Read safety blocks for each
symbol shown.
7 NOTE
Special instructions for best
operation not related to safety.
2
NOTE
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Disconnect input power before
installing or servicing.
WARNING
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
5
4
6
7
1 2
CAUTION
MOVING PARTS can injure.
Keep away from moving parts.
Keep all panels and covers closed
when operating.
3
Turn Off switch when using high frequency.
Figure 1-1. Safety Information
SECTION 2 SPECIFICATIONS
Table 2-1. Welding Generator
Specification Description
Type Of Output CC/CV AC/DC Multiprocess Welding Generator
Rated Weld Output 400 Amperes, 36 Volts DC At 100% Duty Cycle (See Section 2-1)
Amperage Range 45-500 A DC; 40-300 A AC
Max. Open-Circuit Voltage 95 Volts DC; 80 Volts AC
Welding Processes Shielded Metal Arc (SMAW), Gas Metal Arc (GMAW), Flux Cored Arc (FCAW), And Gas Tungsten
Arc Welding (GTAW); Air Carbon Arc Cutting And Gouging (CAC-A)
Engine Deutz F4L912 Air-Cooled, Diesel Engine (See Engine Manual)
Engine Speed (No Load) Weld/Power Speed: 1850 rpm; Idle Speed: 1200 rpm
Fuel Tank Capacity 19 gal (72 L)
Auxiliary Power Plant Single-Phase 10 kVA/kW, 120/240 Volts AC, 42 Amperes, 60 Hz Or Three-Phase 15 kVA/kW, 240
Volts AC, 36 Amperes, 60 Hz
Maximum Auxiliary Power From
Receptacles
Single-Phase 3 kVA/kW, 120 Volts AC, 26 Amperes, 60 Hz
Overall Dimensions See Figure 3-2
Weight Net: 2250 lb (1021 kg); Ship: 2380 lb (1080 kg)
OM-478 Page 2
Table 2-2. Air Compressor
Specification Description
Pressure Output 40 scfm (1.1 scmm), 90 psig (620 kPa), 100% Duty Cycle
Air Tank Capacity 21 gal (79 L)
Tank Pressure Rating 150 psig (1034 kPa)
Safety Relief Valve Rating 130 psig (896 kPa)
Air Control Valve Setting Loads At 90 psig (620 kPa); Unloads At 115 psig (793 kPa)
2-1. Duty Cycle
CAUTION
WELDING LONGER THAN RATED DUTY CYCLE can damage unit and void warranty.
Do not weld at rated load longer than shown below.
warn7.1 8/93
Duty Cycle is percentage of 10
minutes that unit can weld at
rated load without overheating.
Continuous Welding
sb1.1 8/93 SB-121 571-A
0
10
Minutes
100% Duty Cycle At 400 Amperes
Definition
Chart
Figure 2-1. Duty Cycle
2-2. Fuel Consumption
The fuel consumption curve shows
typical fuel use under weld or power
loads.
rsb2.1 10/91 SB-121 494
Figure 2-2. Fuel Consumption Curve
OM-478 Page 3
2-3. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
rsb1.1 10/91 SB-121 492 / SB-121 493 / SB-121 491
A. For AC Mode
B. For Constant Current (CC) DC Mode
C. For Constant Voltage (CV) DC Mode
Figure 2-3. Volt-Ampere Curves
OM-478 Page 4
2-4. AC Auxiliary Power Curves
The ac power curve shows the auxil-
iary power in amperes available at
the 120 and optional 240 volt recep-
tacles, and the single-phase
120/240 volt or three-phase 240
volts terminals.
rsb3.1* 2/92 / rsb13.1 3/92 SB-109 365-B / SB-121 506 / SB-121 505
A. AC Power Curve For Receptacles
B. 10 KVA/KW Single-Phase Auxiliary Power
Plant (No Weld Load)
C. 15 KVA/KW Three-Phase Auxiliary Pow-
er Plant (No Weld Load)
Figure 2-4. AC Power Curves
2-5. Air Compressor Output Curve
SB-121 490
The air output curve shows the vol-
ume and pressure of air available
from the air compressor.
Figure 2-5. Air Compressor Output Curve
OM-478 Page 5
SECTION 3 INSTALLATION
3-1. Selecting A Location And Moving Welding Generator
WARNING
ENGINE EXHAUST GASES can kill.
Do not breathe exhaust fumes.
Use in open, well-ventilated areas, or vent exhaust
outside and away from building air intakes.
ENGINE EXHAUST SPARKS can cause
fire.
Use only U.S. Forestry Department approved spark
arrestor and comply with all local, state, and federal
laws.
A spark arrestor is mandatory in all National Forests
and in grass, brush, or forest covered lands in
California, Oregon, and Washington. Check with
state and local authorities in other areas.
Properly maintain the spark arrestor.
Stop engine and allow exhaust system to cool down
before servicing spark arrestor.
Service spark arrestor away from flammables.
HOT ENGINE EXHAUST AND EXHAUST
PIPE can cause fires.
Keep exhaust and pipe away from flammables.
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
Use lifting eye to lift unit only, NOT running gear, gas
cylinders, trailer, or any other heavy options,
accessories, or devices.
Use equipment of adequate capacity to lift the unit.
TILTING OF TRAILER can result in
personal injury or equipment damage.
Install unit properly on trailer (if applicable)
according to trailer manual.
rwarn1.1 3/93
rsb20.2 5/94 Ref. ST-800 652 / Ref. ST-800 477-A / ST-121 575-B
1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to
move unit.
3 Cross Member Support
If using lifting forks, lift only from end
with cross member support.
4 Trailer
Install unit on trailer according to
trailer manual.
Location And Airflow
OR
OR
1
Movement
2
3
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
4
Figure 3-1. Location And Movement Of Welding Generator
OM-478 Page 6
Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.
NOTE
G
ST-153 650
B
A
C
Inches Millimeters
A 58 1473
B 32 813
C 68 1727
D 1-1/16 27
E 29-7/8 759
F 6-1/8 156
G 9-3/4 248
H 13-3/4 349
J 28-3/16 716
K 36 914
L 46-1/2 1181
M 50-1/2 1283
N 62-3/8 1584
P 21/32 Dia 16.7 Dia
16 Holes 16 Holes
D
E
F
H
J
K
L
M
N
P
Figure 3-2. Overall Dimensions And Base Mounting Hole Layout
Ref. S-0024-B
17.5°
20°
20°
15°
Engine
End
Do not exceed operating
angles while running or en-
gine damage will occur.
Figure 3-3. Maximum Welding Generator Operating Angles
3-2. Installing Precleaners, Exhaust Pipe, And Rain Cap
Stop engine and allow to cool.
Remove rear, left side panel.
1 Air Cleaner
2 Precleaner
Remove tape from air cleaner
openings. Install precleaners onto
air cleaners.
3 Exhaust Pipe
4 Muffler Extension
Remove tape from extension. In-
stall exhaust pipe over extension.
Secure exhaust pipe to top cover
using supplied hardware.
5 Rain Cap
Install cap so it opens toward front
of unit.
Reinstall side panel or go to Section
3-3.
rsb19.4* 5/92 ST-153 652
Do not blow exhaust toward
air cleaner or air intake.
1
2
3
5
4
Tools Needed:
1/2 in
Figure 3-4. Installing Precleaners, Exhaust Pipe, And Rain Cap
OM-478 Page 7
3-3. Connecting The Battery
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.
Stop engine before disconnecting or connecting battery cables.
Always wear a face shield and proper protective clothing when working on a battery.
Do not allow tools to cause sparks when working on a battery.
rwarn2.1 9/91
ST-153 654-B / Ref. ST-118 111-C / Ref. S-0756-B
1 Engine Control Switch
Place switch in the Off position.
Open left side door.
2 Positive (+) Battery Terminal
3 Positive (+) Battery Cable
Connect positive cable first.
4 Negative () Battery Terminal
5 Negative () Battery Cable
Connect negative cable last.
Close side door.
If engine will not crank, check
battery voltage according to
Section 7-8.
Tools Needed:
1/2 in
1
4
+
3
5
2
Figure 3-5. Connecting The Battery
3-4. Engine Prestart Checks
ENGINE FUEL can cause fire or
explosion.
Stop engine before fueling.
Do not fuel while smoking or near sparks or flames.
Do not overfill tank; clean up any spilled fuel.
USE OF GASOLINE will damage engine.
Do not use gasoline.
Lack of lubrication in gasoline damages injector pump
and injectors.
REMOVE FUEL CAP SLOWLY; FUEL
SPRAY may cause injury; FUEL may be
under pressure.
Rotate fuel cap slowly and wait until hissing stops
before removing cap.
WARNING
rwarn3.1* 3/93
rsb4.2* 11/92 Ref. ST-153 653
Check all fluids daily. Engine must
be cold and on a level surface.
Add fresh fuel before starting
engine the first time (see
Figure 7-2).
1 Fuel Cap
Do not run out of fuel or air enters
fuel system and causes starting
problems.
2 Oil Dipstick
3 Oil Fill Tube
If oil is not up to full mark, add oil
(see Figure 7-2).
Follow break-in procedure in
engine manual.
If unburned fuel and oil collect in ex-
haust pipe during break-in, see
Section 9.
Tools Needed:
3/8 in
OIL
2
Full
FUEL
Full
1/2 in
(13 mm)
1
3
Figure 3-6. Checking Fuel And Oil
OM-478 Page 8
3-5. Grounding The Generator Auxiliary Power System And Lower Panel Components
3/8, 1/2 in
rsb5.1* 8/93 Ref. ST-121 578-C
Open lower front door.
1 Jump Start/Battery Charge
Receptacle (Optional)
(Section 6)
2 Remote Terminal Strip
(Section 3-8)
3 Remote 14 Receptacle
(Section 3-8)
4 Equipment Grounding
Terminal
5 Electrode Weld Output
Terminal (Section 3-7)
6 Work Weld Output Terminal
(Section 3-7)
7 Bar
Route all cables under bar.
8 Air Compressor Fitting
(Section 3-9)
Close door.
Tools Needed:
12
3
56
7
8
Connect To Earth Ground
If Required By National
Or Local Codes
The generator auxiliary power neutral
is connected to the machine frame.
4
Figure 3-7. Equipment Grounding Connection And Lower Panel Components
3-6. Selecting And Preparing Weld Output Cables
sb6.5 5/94 S-0752
1 Weld Output Cable
Determine total cable length in weld
circuit and maximum welding am-
peres. Use Table 3-1 to select prop-
er cable size.
Use shortest cables possible.
Do not use damaged cables.
2 Terminal Lug
Use lugs of proper amperage
capacity and hole size for connect-
ing to work clamp, wire feeder or
electrode holder, and weld output
terminals.
3 Wire Feeder
4 Insulated Electrode Holder
5 GTAW Torch
Install according to manufacturer’s
instructions.
6 Work Clamp
Install onto work cable.
Tools Needed:
10 ft (3 m)
1
Total Cable
Length In Weld
Circuit = 20 ft (6 m)
10 ft (3 m)
For Example,
2
6
3
2
54
OR OR
Figure 3-8. Selecting And Preparing Weld Output Cables
OM-478 Page 9
Table 3-1. Weld Cable Size*
Total Cable (Copper) Length In Weld Circuit Not Exceeding
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)
Welding
Amperes
10 To 60%
Duty Cycle
60 Thru 100%
Duty Cycle
10 Thru 100% Duty 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
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0
*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
3-7. Connecting To Weld Output Terminals
WARNING
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Stop engine before making any weld output connections.
Do not let torch cable adapter hit screwheads, access door, case, or any parts.
Install adapter as shown in Figure 3-9.
rwarn9.1* 3/94
1
2
1 Work Weld Output Terminal
2 Electrode Weld Output Terminal
3 Torch Cable Adapter
Adapter connects power and water to
torch and cooling system or drain.
4 Access Door
Connect cables as shown.
Close and secure access door.
Tools Needed:
3/8, 3/4 in
SMAW Connections GTAW Connections
Work
Work
OR
Use only a proper torch cable
adapter positioned so it does
not hit frame, hardware, or
door during operation.
sb9.1 12/94 Ref. ST-121 578-C / Ref. ST-150 972-A / ST-800 578
Location of Terminals
Gas Or
Water Hose
1
2
3
1
2
4
Figure 3-9. Weld Output Connections
OM-478 Page 10
3-8. Remote 14 Receptacle Or Terminal Strip Connections
A. Remote 14 Receptacle Connections
sb7.1 5/94 Ref. ST-800 729 / Ref. S-0004-A / S-0750 / Ref. ST-141 127-B
1 Remote 14 Receptacle RC3
(See Table 3-2)
Remove cover from receptacle.
2 Keyway
3 Plug
4 Threaded Collar
To connect to receptacle, align
keyway, insert plug, and tighten
threaded collar.
3
4
OR
AJ
B
K
I
C
L
NH
D
M
G
E
F
1
2
Figure 3-10. Remote 14 Connections
Table 3-2. Remote 14 Socket Information
A 24 volts ac. Protected by circuit breaker CB4.
B Contact closure to A completes 24 volts ac contactor control circuit.
I 115 volts ac. Protected by circuit breaker CB3.
J Contact closure to I completes 115 volts ac contactor control circuit.
G Circuit common for 24 and 115 volts ac circuits.
C +10 volts dc output to remote control.
D Remote control circuit common.
E 0 to +10 volts dc input command signal from remote control.
K Chassis common.
Socket Information
*The remaining sockets are not used.
Socket*
OM-478 Page 11
B. Terminal Strip 3T Connections
WARNING
ELECTRIC SHOCK can kill; UNEXPECTED OUTPUT can cause serious injury.
Do not touch live electrical parts.
Stop engine before making any internal inspection or connections.
Do not connect to Remote 14 receptacle and terminal strip at the same time.
Output (Contactor) can be energized from either the receptacle or terminal strip. Use only one remote control method.
Ref. ST-150 972-A
Stop engine.
Remove plug from remote control
cord.
1 Terminal Strip 3T
Remove clear plate from 3T.
Connect leads to 3T using terminal
information shown in Table 3-2.
Reinstall clear plate. Close door.
Tools Needed:
3/8 in
1
Figure 3-11. Terminal Strip 3T Connections
3-9. Air Compressor Connections
ST-800 727
Air compressor operates whenever
engine is running.
1 1/2 in NPT Air Compressor
Fitting
Obtain and connect quick-
disconnect and air hose to fitting.
2 Air Shutoff Valve
Be sure valve is in open position
when using air compressor.
Open Position Closed Position
2
1
Figure 3-12. Air Compressor Connections
OM-478 Page 12
3-10. Installing Ether Cylinder (Optional Ether Starting Aid)
WARNING
IMPROPER HANDLING OR EXPOSURE TO ETHER
can seriously harm your health.
Follow manufacturer’s safety instructions on cylinder.
INJECTING ETHER WHILE ENGINE IS RUNNING
can damage engine.
Do not use Ether Starting Aid while engine is running.
After installing cylinder, wait at least 10 minutes before use to let ether
particles settle to prevent atomizer plugging.
rsb15.1 6/92A ST-153 382
Stop engine. Open side door(s) to
locate ether starting aid.
1 Ether Cylinder
Obtain cylinder.
2 Nozzle
Remove protective cover, and
clean nozzle and fitting area on
cylinder.
3 Clamp
4 Fitting
5 Valve Cap
6 Valve
Remove valve cap, and clean fitting
area.
Insert cylinder through clamp and
onto fitting.
Tighten clamp when cylinder is tight
in fitting.
Put cap on fitting when cylinder is
removed.
1
2
3
4
6
5
Figure 3-13. Installing Ether Cylinder
SECTION 4 OPERATING THE WELDING GENERATOR
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Stop engine before installing or servicing.
Keep all panels and covers securely in place.
WELDING can cause fire or explosion.
Do not weld near flammable material.
Watch for fire; keep extinguisher nearby.
Do not locate unit over combustible surfaces.
Do not weld on closed containers.
Allow work and equipment to cool before handling.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Wear welding helmet with correct shade of filter.
Wear correct eye, ear, and body protection.
FUMES AND GASES can be hazardous.
Keep your head out of the fumes.
Ventilate area, or use breathing device.
Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
ENGINE EXHAUST GASES can kill.
Do not breathe exhaust fumes.
Use in open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
ENGINE FUEL can cause fire or explo-
sion.
Stop engine before fueling.
Do not fuel while smoking or near sparks or flames.
Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.
Keep away from moving parts such as fans, belts,
and rotors.
Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near any welding operations.
See Safety Precautions at beginning of manual for ba-
sic welding safety information.
WARNING
rwarn5.1 10/91
OM-478 Page 13
1 Voltmeter
2 Ammeter
3 Amperage And Voltage
Adjustment Control
4 Ether Starting Aid Switch
(Optional)
5 Battery Check Light (Optional)
6 Battery Voltage Selector Switch
(Optional)
7 Amperage & Voltage Control
Switch
8 CC/CV Switch
9 Output (Contactor) Switch
10 Battery Charge/Jump Start
Switch (Optional)
11 Service Engine Air Cleaner
Light (Section 7-2)
12 Engine Control Switch
13 Check Cooling System/
Alternator Light (Section 7-2)
14 Service Compressor Air
Cleaner Light (Section 7-2)
15 Fuel Gauge
16 Air Pressure Gauge
17 Battery Ampere Gauge
18 Air Tank Moisture Drain Control
(Section 7-2)
19 Oil Pressure Gauge/Switch
20 Oil Temperature Gauge/Switch
21 Engine Hour Meter
22 Output Selector Switch
23 Ampere Ranges Switch
Ref. ST-121 578-C
12 3 456789
10
11
12
13
14
15
16
17
18
23 22 21 20 19
Figure 4-1. Controls
Wear the following while welding:
1 Dry, Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)
sb3.1 1/94
123
Figure 4-2. Safety Equipment
1 Work Clamp
Connect work clamp to a clean,
paint-free location on workpiece, as
close to weld area as possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
sb4.1 2/93
Tools Needed:
1
Figure 4-3. Work Clamp
OM-478 Page 14
1 CC/CV Switch
Use switch to select type of weld
output.
Use constant current (CC) position
for SMAW, GTAW, and CAC-A.
Use constant voltage (CV) position
for GMAW and FCAW process.
When using CV position, place Am-
pere Ranges switch in CV position
(see Figure 4-6).
Ref. ST-118 111-C
1
Figure 4-4. CC/CV Switch
WARNING
WARNING: ELECTRIC SHOCK can kill.
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.
Read Safety Precautions at beginning of this
manual.
ARCING can damage switch.
Do not change Output Selector switch position while
welding.
Arcing inside switch can damage contacts, causing
switch to fail.
warn6.3 4/92 / rwarn6.1* 2/93
1 Output Selector Switch
Use switch to select polarity of weld
output.
For Direct Current Electrode
Negative (DCEN), use Electrode
Negative position.
For Direct Current Electrode
Positive (DCEP), use Electrode
Positive position.
For alternating current (AC), use
AC position.
1
Figure 4-5. Output Selector Switch
OM-478 Page 15
CAUTION
ARCING can damage switch.
Do not change Ampere Ranges switch position while welding.
Arcing inside switch can damage contacts, causing switch to fail.
rwarn6.1 2/93
1 Ampere Ranges Switch
Use switch to select range of weld
output.
If Output Selector switch is in
Electrode Negative or Electrode
Positive position, set switch
according to DC scale.
If Output Selector switch is in the
AC position, set switch according to
AC scale.
1
For best arc starts, use
lowest amperage range
possible.
Figure 4-6. Ampere Ranges Switch
WARNING
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Do not touch weld output terminals when engine is running.
Do not touch electrode and work clamp at the same time.
rwarn7.1 9/91
1 Output (Contactor) Switch
Use switch to select way of
controlling unit output.
For weld output, place switch in On
position.
For remote output control, place
switch in Remote position (see
Section 3-8).
Weld output terminals are
energized when switch is
On and engine is running.
1
Figure 4-7. Output (Contactor) Control Switch
OM-478 Page 16
1 Amperage And Voltage
Adjustment Control
Use control to adjust amperage or
voltage within range selected by
Ampere Ranges switch (see
Figure 4-6). Numbers around
control are for reference only.
1
Example Of Front Panel Amperage And Voltage Control
Set Range Set Percentage Weld Output = 82.5 A DC
In Example:
Range = 55 to 110 A DC
Percentage Of Range = 50%
Weld Output = 82.5 A DC
(50% of 55 to 110)
Figure 4-8. Amperage And Voltage Adjustment Control
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Miller AIR PAK Owner's manual

Category
Welding System
Type
Owner's manual
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