Miller Electric 280 NT Owner's Manual
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Miller Electric 280 NT Owner's Manual

Engine driven welding generator
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www.MillerWelds.com
Miller Legend 302
OM-4430
217 243R
2007−04
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding &
Flux Cored (FCAW) Welding
With Voltage Sensing Feeder
Description
Engine Driven Welding Generator
R
File: Engine Drive

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Summary of Contents for Miller Electric 280 NT

  • Page 1 Visit our website at www.MillerWelds.com Miller Legend 302 OM-4430 217 243R 2007−04 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding & Flux Cored (FCAW) Welding With Voltage Sensing Feeder Description Engine Driven Welding Generator File: Engine Drive...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage ............... 1-2.
  • Page 4 TABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance ..............8-2.

  • Page 5: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 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 explained in the text.
  • Page 6 FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.

  • Page 7: Engine Hazards

    1-3. Engine Hazards BATTERY EXPLOSION can BLIND. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Stop engine before disconnecting or connect- ing battery cables or servicing battery. D Do not allow tools to cause sparks when working on a battery. D Do not use welder to charge batteries or jump start vehicles.

  • Page 8: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and gouging can cause fire or explosion. D Do not cut or gouge near flammables. D Watch for fire; keep extinguisher nearby. HOT PARTS can cause burns and injury. D Do not touch hot compressor or air system parts.

  • Page 9: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

  • Page 10: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − 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 blessures graves.
  • Page 11 Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation. D 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. D Ne pas toucher à...

  • Page 12: Dangers Existant En Relation Avec Le Moteur

    D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 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 affec l’ouïe. D Porter des protections approuvés pour les ore les si le niveau sonore est trop élevé.

  • Page 13: Dangers Liés À L'air Comprimé

    D 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. D Les fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore.
  • Page 14 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. D Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur. D Ne pas laisser tourner le moteur trop lentement sous risque d’en- dommager le moteur électrique à cause d’une tension et d’une fré- quence trop faibles.

  • Page 15: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements 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...

  • Page 16: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Start Engine Engine Oil Engine MIG (GMAW), Wire Positive Time Do not switch while welding Wire Feed Notes OM-4430 Page 12 Fast Fast/Slow (Run, Weld/Power) (Run/Idle) Panel/Local Temperature Check Valve Engine Choke Clearance Read Operator’s Amperes...

  • Page 17: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Description This multiprocess engine-driven welder and AC generator provides low speed generator AC power and DC weld out- put for quiet, fuel-efficient operation. At 1800 rpm, this unit produces 5 kW/kVA 60 Hz 120/240 Volt AC generator power.

  • Page 18: Dimensions For Units With Optional Running Gear

    4-4. Dimensions For Units With Optional Running Gear Dimensions All Running Gear Options: 42-1/2 in (1079 mm) Height (To Top Of Handle Assembly) Protective Cage Width: 26 in (660 mm) Running Gear Width: 32 in (813 mm) Protective Cage Length: 48 in (1219 mm) Running Gear Length: 45−1/2 in (1156 mm)

  • Page 19: Generator Power Curve

    4-6. Generator Power Curve Notes WELD POSITION: FLAT BUTT WELD JOINT TYPES GROOVE FILLET T−JOINT Ref. AWS/ANSI D1.1 AC AMPERES HORIZONTAL VERTICAL BUTT T−JOINT The ac generator power curve shows the generator power avail- able in amperes at the receptacles. 222 553 OVERHEAD BUTT...

  • Page 20: Duty Cycle

    4-7. Duty Cycle 100% Duty Cycle at 280 Amperes DC/CC 4-8. TIG Mode Volt-Ampere Curves OM-4430 Page 16 Continuous Welding % DUTY CYCLE 3600RPM Max 3000RPM Max DC AMPERES Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating.

  • Page 21: Stick And Mig Mode Volt-Ampere Curves

    4-9. Stick And MIG Mode Volt-Ampere Curves A. CC/DC Stick Mode 3000RPM Max B. CV/DC MIG Mode 20V Preset 3600RPM Max DC AMPERES 3600RPM Max 3000RPM Max DC AMPERES The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator.

  • Page 22: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Movement Do not lift unit from end. Location / Airflow Clearance 18 in (460 mm) 18 in (460 mm) 18 in 18 in (460 mm) (460 mm) Mounting Inadequate support. Do not use flexible mounts. Grounding GND/PE Electrically bond generator frame to...

  • Page 23: Engine Prestart Checks

    5-2. Engine Prestart Checks Full Empty Full Gasoline 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: Connecting Or Replacing The Battery

    5-3. Connecting Or Replacing The Battery Replacing The Battery Tools Needed: 3/8, 1/2 in OM-4430 Page 20 Connect negative (−) cable last. − Remove end panel to replace battery. Connect negative (−) cable last. − − 803 847 / 803 849 / Ref. S-0756-D Ref 216 172-D / Ref 803 983−A...

  • Page 25: Installing Exhaust Pipe

    5-4. Installing Exhaust Pipe Tools Needed: 1/2 in Notes 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 always away from front panel and direction of travel.

  • Page 26: Connecting To Weld Output Terminals

    5-5. Connecting To Weld Output Terminals Do not place anything between weld cable terminal and copper bar. Correct Installation Tools Needed: 3/4 in OM-4430 Page 22 Stop engine. Do not connect to CC and CV terminals at the same time. Negative (−) Weld Output Terminal Stick/TIG (CC) Weld Output...

  • Page 27: Selecting Weld Cable Sizes

    5-6. Selecting Weld Cable Sizes* Weld Output Terminals Stop engine before connecting to weld output terminals. Do not use worn, damaged, under- sized, poorly spliced cables. Welding Amperes This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable. **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.

  • Page 28: Section 6 − Operating Welding Generator

    SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls Process Switch See Section 6-5 for Process switch informa- tion. Remote Receptacle Use receptacle to connect remote control. When a remote voltage/amperage control is connected to the Remote receptacle, the Auto Sense Remote feature automatically switches voltage/amperage control to the re- mote control (see Sections 5-7 and 6-8).

  • Page 29: Description Of Engine Controls (See Section 6-1)

    6-2. Description Of Engine Controls (See Section 6-1) Engine Control Switch Use 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 at 2400 rpm no weld load and 3600 rpm under weld load.

  • Page 30: Controlling Engine Speed And Weld/Generator Output

    6-4. Controlling Engine Speed And Weld/Generator Output Engine Controls Engine Speed Either Run/Idle 1800 rpm position. (Power Speed) Continuous No Load: 2400 rpm (Idle Speed) Load: 3600 rpm (Weld Speed) No Load: 1800 rpm (Idle Speed) Load: 3000 rpm (Weld Speed) OM-4430 Page 26 Generator Power Weld Output...

  • Page 31: Process Switch

    6-5. Process Switch 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 between pins A and B on re- mote receptacle).

  • Page 32: Stick Start Procedure − Scratch Start Technique

    6-6. Stick Start Procedure − Scratch Start Technique 6-7. TIG Lift-Arc Start Procedure Lift-Arc Start Method “Touch” Do NOT Strike Like A Match! OM-4430 Page 28 Second With Stick selected, start arc as follows: Electrode Workpiece Drag electrode across workpiece like striking a match;...

  • Page 33: Remote Voltage/Amperage Control

    6-8. Remote Voltage/Amperage Control Connect Remote Set Process V/A Control To Remote Receptacle RC4 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 control voltage/ amperage settings.

  • Page 34: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 60 Hz Generator Power Receptacles And Supplementary Protectors Controlling Engine Speed And Weld/Generator Power Output Engine Controls Engine Speed Either Run/Idle 1800 rpm position. (Power Speed) Continuous No Load: 2400 rpm (Idle Speed) Load: 3600 rpm (Weld Speed) No Load: 1800 rpm...

  • Page 35: Variable Frequency (Hz) Generator Power Receptacle Rc3

    7-2. Variable Frequency (Hz) Generator Power Receptacle RC3 Notes Work like a Pro! NOTICE − Do not operate equipment requiring a constant frequency from variable frequency receptacle RC3. 120 V 20 A Variable Frequency AC Receptacle RC3 Receptacle supplies single-phase power continuously.

  • Page 36: Wiring Instructions For Optional 240 Volt, Single-Phase Plug (Nema 14-50P)

    7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) Current Available in Amperes 240 V Each 120 V Duplex Receptacle* Receptacle V x A = Watts *One 240 V load or two 120 V loads. OM-4430 Page 32 120V 120V 240V...

  • Page 37: Section 8 − Maintenance & Troubleshooting

    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. n = Check Z = Change * To be done by Factory Authorized Service Agent Every Hours n Fuel Level...

  • Page 38: Maintenance Label

    A complete Parts List is available at www.MillerWelds.com 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. OM-4430 Page 34...

  • Page 39: Servicing Optional Spark Arrestor

    8-3. Servicing Optional Spark Arrestor Tools Needed: 1/4 in 8-4. Servicing Air Cleaner Stop engine and let cool. Spark Arrestor Screen Clean and inspect screen. Replace spark arrestor if screen wires are broken or missing. 803 983−A / Ref 216 172-D Stop engine.

  • Page 40: Changing Engine Oil, Oil Filter, And Fuel Filter

    8-5. Changing Engine Oil, Oil Filter, And Fuel Filter Full Tools Needed: OM-4430 Page 36 Stop engine and let cool. Oil Drain Valve Oil Filter Change engine oil and filter accord- ing to engine manual. NOTICE − Close valve and valve cap before adding oil and running engine.

  • Page 41: Overload Protection

    8-6. Overload Protection 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. Supplementary Protector CB4 CB4 protects the stator winding supplying 24 volt ac output to Re- mote receptacle RC4.

  • Page 42: Troubleshooting

    8-7. Troubleshooting A. Welding Trouble 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 Sections 6-1 and 6-8). Check and secure connections to Remote receptacle RC4 (see Sections 5-7). Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
  • Page 43 Trouble Lack of high frequency; difficulty in Use proper size tungsten for welding amperage. establishing Gas Tungsten Arc Weld- ing arc. Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive coils from weld cables, use shorter weld cables, etc.). Check cables and torch for cracked or deteriorated insulation or bad connections.
  • Page 44 D. Engine Trouble 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 Engine Control switch S2. Engine does not start.

  • Page 45: Section 9 − Parts List

    SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Dia. Part Mkgs....021718 ....215984 .

  • Page 46: Section 10 − Electrical Diagrams

    SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welding Generator Models OM-4430 Page 42...
  • Page 47 232 961-A OM-4430 Page 43...

  • Page 48: Section 11 − Generator Power Guidelines

    SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 11-1. Selecting Equipment 11-2. Grounding Generator To Truck Or Trailer Frame GND/PE OM-4430 Page 44 Generator Power Receptacles −...

  • Page 49: Grounding When Supplying Building Systems

    11-3. Grounding When Supplying Building Systems 11-4. How Much Power Does Equipment Require? GND/PE VOLTS 115 AMPS Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home,...
  • Page 50 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 11-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 51 11-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
  • Page 52 11-8. Power Required To Start Motor Motor Start Code KVA/HP 11-9. How Much Power Can Generator Supply? OM-4430 Page 48 Single-Phase Induction Motor Starting Requirements 10.0 AC MOTOR VOLTS AMPS CODE PHASE 11.2 12.5 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to...
  • Page 53 11-10. Typical Connections To Supply Standby Power Utility Electrical Transfer Switch Service Essential Loads Fused Welding Disconnect Generator Switch Output (If Required) Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install and ground this equipment according to its Owner’s Manual and na- tional, state, and local codes.
  • Page 54 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
  • Page 55 Notes SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) Specifications Socket or Wrench Size Bolt Decimal Bolt Diameter Equivalent 1/4 in .250 in 3/8 in 5/16 in .3125 in 1/2 in 3/8 in .375 in 9/16 in 7/16 in .4375 in 5/8 in 1/2 in .500 in 3/4 in...
  • Page 56 Notes Welding Symbols Ref. AWS/ANSI A2.4 OM-4430 Page 52...
  • Page 59 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.

  • Page 60: Options And Accessories

    File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2007 Miller Electric Mfg. Co. 2007−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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Legend 302

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