Miller Electric Metro 250D Owner's Manual
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Miller Electric Metro 250D Owner's Manual

Miller metro 250d owner's manual
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Metro 250D
OM-402B
April 1997
Eff. w/Serial Number KH383240
Processes
Shielded Metal Arc
(Stick) Welding
Gas Tungsten Arc
(TIG) Welding
With Optional Equipment:
Flux Cored Arc Welding
Description
Engine Driven Welding Generator

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Summary of Contents for Miller Electric Metro 250D

  • Page 1 Visit our website at www.MillerWelds.com Metro 250D OM-402B April 1997 Eff. w/Serial Number KH383240 Processes Shielded Metal Arc (Stick) Welding Gas Tungsten Arc (TIG) Welding With Optional Equipment: Flux Cored Arc Welding Description Engine Driven Welding Generator...
  • Page 2 ISO 9001 Quality System Standard. service information for your 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 catalog sheets.

  • Page 3: Table Of Contents

    16 hours on one tank of fuel. The low noise case provides remarkably quiet operation, 99 LW(A) or 74 dB(A) at 23 ft (7 m), making the Metro 250D an excellent machine for work in noise-restricted locations.

  • Page 5: Symbol Usage

    1. Safety Precautions − Read Before Using Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. Arc Welding Hazards Y The symbols shown below are used throughout this manual to call attention to and identify possible hazards.

  • Page 6: Engine Hazards

    WELDING can cause fire or explosion. 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.
  • Page 7 MOVING PARTS can cause injury. D Keep away from fans, belts, and rotors. D Keep all doors, panels, covers, and guards closed and securely in place. D Stop engine before installing or connecting unit. D Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary.

  • Page 8: Principal Safety Standards

    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 prompt- ly correct any interference problem resulting from the installa- tion.

  • Page 9: Signification Des Symboles

    1. Consignes de sécurité − lire avant utilisation Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. Signifie NOTA ;...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- cendie ou une explosion. Le soudage effectué 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.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements protection. D Arrêter le moteur avant d’installer ou brancher l’appareil. D Demander seulement à...
  • Page 12 ÉLECTROSTATIQUES endommager les circuits imprimés. D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes. UNE REMORQUE QUI BASCULE peut entraîner des blessures.

  • Page 13: Symbols And Definitions

    2. Definitions Symbols and Definitions Stop Engine Start Engine Engine Oil Check Injectors/ Pump Amperes Engine-Driven, Single-Phase Alternator With Rectifier Positive Certified/Trained Mechanic Output Rated Load Speed Current Hours OM-402 Fast (Run, Weld/Power) Glow Plug Remote 14 Check Valve Clearance Stick (SMAW) Engine Negative...

  • Page 14: General Precautionary Label

    General Precautionary Label A. Warning! 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. Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand.
  • Page 15 Battery Charging Label Warning! Watch Out! There are possible hazards as shown by the symbols. Do not smoke and keep matches and flames away from battery. Sparks can cause battery gases to explode. Battery explosion can blind and injure. Wear a face shield. Battery acid can burn skin.
  • Page 16 Hot Muffler Label Warning! Watch Out! There are possible hazards as shown by the symbols. Hot muffler and exhaust pipes can cause severe burns. Do not touch hot muffler or pipes. Diesel Fuel Label Warning! Watch Out! There are possible hazards as shown by the symbols.
  • Page 17 Falling Equipment Label Warning! Watch Out! There are possible hazards as shown by the symbols. Falling equipment can cause serious injury and damage. Use lifting eye to lift or move unit only. proper equipment when lifting. Do not use lifting eye to lift and support unit and trailer or other heavy devices or accessories.

  • Page 18: Manufacturer's Rating Label

    Read Owner’s Manual. Use glow plugs for 10−25 seconds to aid starting in cold weather. 2.10 Manufacturer’s Rating Label 60 Hz METRO 250D 20A/21V = 58V 20A/11V = 58V −1 n = 3600 min −1...

  • Page 19: Specifications

    3. Specifications Weld, Power, and Engine Specifications Maximum Rated Welding Amperage Open-Circuit Output Range Voltage DC 280 A, 31 V DC, 60% Duty Cycle 20 − 280 250 A, 30 V DC, (Average) 100% Duty Cycle Dimensions, Weights, and Operating Angles Dimensions Height 41 in (1041 mm)

  • Page 20: Duty Cycle And Overheating

    Fuel Consumption Duty Cycle and Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit void warranty. 60% Duty Cycle At 280 Amperes 6 Minutes Welding 4 Minutes Welding 100% Duty Cycle At 250 Amperes 6 Minutes Resting...

  • Page 21: Installing Welding Generator

    AC Auxiliary Power Curve The auxiliary power curve shows the auxiliary power in amperes available at the receptacles. 4. Installation Installing Welding Generator Generator Base Movement Metal Vehicle Frame Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire.

  • Page 22: Engine Prestart Checks

    Connecting Battery and Installing Exhaust Pipe Y Stop engine. Installation of exhaust pipe is optional. Engine Prestart Checks Check all fluids daily. Unit must be cold and on a level surface. Oil may be added at either oil fill. Engine stops if oil pressure is low. Y Heavy loading during first 50 hours will damage engine.

  • Page 23: Connecting To Weld Output Terminals

    Connecting to Weld Output Terminals Positive (+) Weld Output Terminal Negative (−) Weld Output Terminal For Direct Current Electrode Positi- ve (DCEP), connect work cable to Negative (−) terminal and electrode cable (Stick) or torch cable (TIG) to Positive (+) terminal. For Direct Current Electrode Nega- tive (DCEN), reverse cable con- nections.

  • Page 24: Remote 14 Receptacle Rc1 Information

    Remote 14 Receptacle RC1 Information Ref. ST-158 93 C L N *The remaining sockets are not used. Socket* 24 volt ac with respect to socket G. Protected by circuit breaker CB5. Contact closure to A completes 24 volt ac contactor control circuit.

  • Page 25: Front Panel Controls

    5. Operating the Welding Generator Front Panel Controls Y Heavy loading during first 50 hours will damage engine. Keep load less than 225A (weld) or 7 kVA (power) for first 50 hours. Engine Control Switch Use switch to operate glow plug (optional − see table), start engine, select speed, and stop engine.
  • Page 26 Remote Amperage and Contactor Control Y Weld output terminals are energized when Output (Contactor) Control switch is On and engine is running. 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.

  • Page 27: Auxiliary Power Receptacles

    120/240 V 42 A AC Straight Receptacle RC3 120/240 V 42 A AC Twistlock Receptacle RC4 (Optional) RC1 and RC2 supply 60 Hz single-phase power at weld/power speed. Maximum out- METRO 250D 60 Hz 240 V 280 A 1.3 kVA 250 A 2.5 kVA...

  • Page 28: Routine Maintenance

    7. Maintenance & Troubleshooting Routine Maintenance Check fluid levels. See Section 4.3. 50 h Clean air filter element. See Section 7.5. 100 h Change oil. See Section 7.3 and maintenance label. 200 h Change oil filter. See Section 7.3 and maintenance label.
  • Page 29 DEUTZ/RUGGERINI RD211 DIESEL ENGINE 8 Hrs. 12 V −1 2200 min BCI 58 Î Î −1 430 A @ 0 F (-18 C) 3700 min 50 Hrs. Deutz 77-644-39 Deutz 77-656-19 DIN 51 601 BS 2869: A1, A2 ASTM D 975-81: 1-D, 2-D VV-F 800C: DF-A, DF-1, DF-2 S t = .5% DIESEL...

  • Page 30: Changing Engine Oil And Oil Filter

    Changing Engine Oil and Oil Filter Y Stop engine. See engine manual for oil/filter change procedure. Drain oil while engine is warm. Oil Fill Caps (Use Either Cap) Oil Drain Valve Y Close oil drain valve and cap before adding running engine.

  • Page 31: Servicing Air Cleaner

    Changing Fuel Filters Y Stop engine and let cool. Secondary Fuel Filter Remove filter. Apply thin film of oil to gasket on new filter. Install filter. Primary Fuel Filter Fuel Line Remove filter. Inspect all fuel lines and replace if cracked or worn. Install new filter and clamps.

  • Page 32: Adjusting Engine Speed

    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 Turn Engine Control switch to Run/ Idle position. Idle Speed Lock Nut Idle Speed Screw Loosen nut.

  • Page 33: Overload Protection

    Overload Protection Y 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. Weld Auxiliary Power Circuits Fuse F2 F2 protects battery excitation circuit.

  • Page 34: Servicing Optional Spark Arrestor

    Servicing Optional Spark Arrestor Y Stop engine and let cool. Spark Arrestor Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 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 fireproof material.

  • Page 35: Engine Troubleshooting

    Trouble 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 SR3, capacitor C5, and circuit board PC6.
  • Page 36 Trouble 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 necessary.
  • Page 37 Notes OM-402...

  • Page 38: Electrical Diagram

    8. Electrical Diagram Circuit Diagram for Welding Generator OM-402...
  • Page 39 SC-181 758 OM-402...

  • Page 40: Run-In Procedure

    9. Run-In Procedure Wetstacking Y Heavy loading during first 50 hours will damage engine. Keep load less than 225A (weld) or 7 kVA (power) for first 50 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 run-in.

  • Page 41: Run-In Procedure Using Load Bank

    Run-In Procedure Using Load Bank Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Load Bank Turn all load bank switches Off. If needed, connect load bank to 115 volts ac wall receptacle or genera- tor auxiliary power receptacle.

  • Page 42: Run-In Procedure Using Resistance Grid

    Run-In Procedure Using Resistance Grid Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/ grid. Y Keep exhaust and pipe away from flammables. Resistance Grid Use grid sized for generator rated output. Turn Off grid. Welding Generator Set Amperage control at min.

  • Page 43: Grounding Generator To Truck Or Trailer Frame

    10. Auxiliary Power Guidelines 10.1 Selecting Equipment Auxiliary Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment 10.2 Grounding Generator to Truck or Trailer Frame Generator Base Metal Vehicle Frame Equipment Grounding Terminal Grounding Cable...

  • Page 44: Grounding When Supplying Building Systems

    10.3 Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. Ground Device Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. 10.4 How Much Power Does Equipment Require? Resistive Load A light bulb is a resistive load and requires a constant amount of pow-...
  • Page 45 10.5 Approximate Power Requirements for Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 10.6 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 46 10.7 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 47: Power Required To Start Motor

    10.8 Power Required to Start Motor Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage.
  • Page 48 10.10 Typical Connections to Supply Standby Power Power Company Service Meter Main and Branch Overcurrent Protection Double-Pole, Double-Throw Transfer Switch Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection. Circuit Breakers or Fused Disconnect Switch Obtain and install correct switch.

  • Page 49: Selecting Extension Cord (Use Shortest Cord Possible)

    10.11 Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y 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 Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 50: Parts List

    11. Parts List 11.1 Main Assembly Hardware is common and not available unless listed. Fig 11-2 Fig 11-4 OM-402...
  • Page 51 OM-402 Fig 11-3 ST-801 488-A...
  • Page 52 11.1 (Continued) Item Dia. Part Mkgs....+163 828 ....164 507 .
  • Page 53 11.1 (Continued) Item Dia. Part Mkgs....173 931 ....167 313 .
  • Page 54 11.1 (Continued) Item Dia. Part Mkgs....162 515 ..C1,3 ..048 420 .
  • Page 55 11.2 (Continued) Hardware is common and not available unless listed. 24 25 Item Dia. Part Mkgs... . . 083 432 ....039 046 .
  • Page 56 11.3 Generator (Fig 11.1 Item 56) Hardware is common and not available unless listed. Item Part ... . . 166 770 STUD, stl .375-16 x 19.750 ... . . 160 943 ENDBELL .
  • Page 57 11.4 Control Box w/Components (Fig 11.1 Item 86) Hardware is common and not available unless listed. Item Dia. Part Mkgs..D1,5 . . . 135 184 ....038 889 .
  • Page 58 Notes OM-402...
  • Page 59 Notes...
  • Page 60 Notes OM-402...
  • Page 61 Notes...

  • Page 62: Options And Accessories

    12. Options and Accessories 12.1 Metro 250D WELD METERS − DC AMP & VOLT (#042 947 Field) Machine is prewired for easy installation of field kit. STARTING AID KITS (#043 139 Field) Improve starting in cold weather by adding air intake manifold glow plug. Machine is prewired.
  • Page 63 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 64: Owner's Record

    Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA &...

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