Miller Trailblazer 280 NT Owner's Manual
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Miller Trailblazer 280 NT Owner's Manual

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Trailblazer 280 NT
OM-4402
March 2000
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Plasma Cutting and Gouging
R
with Spectrum
Unit
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
R
199101

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Summary of Contents for Miller Trailblazer 280 NT

  • Page 1 MIG (GMAW) Welding Flux Cored (FCAW) Stick (SMAW) Welding TIG (GTAW) Welding Air Plasma Cutting and Gouging with Spectrum Unit Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator Trailblazer 280 NT Visit our website at www.MillerWelds.com...
  • Page 2 − every power source from This Owner’s Manual is designed to help you get the most out of your Miller is backed by the most Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the business.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ......1-1. Symbol Usage .

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

    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. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.

  • Page 6: Engine Hazards

    WELDING can cause fire or explosion. HOT PARTS can cause severe burns. D Allow cooling period before maintaining. Welding on closed containers, such as tanks, D Wear protective gloves and clothing when drums, or pipes, can cause them to blow up. Sparks working on a hot engine.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    READ INSTRUCTIONS. stopping engine. D Do not let low voltage and frequency caused by D Use only genuine MILLER replacement parts. low engine speed damage electric motors. D Perform engine maintenance and service D Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle according to this manual and the engine where applicable.

  • Page 8: Principal Safety Standards

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment perform this installation.

  • Page 9: Section 1 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom _nd_fre 11/98 1-1. 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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. D Prévoir une période de refroidissement avant d’effec- Le soudage effectué sur des conteneurs fermés tels que tuer des travaux d’entretien. des réservoirs, tambours ou des conduites peut provoquer leur éclatement.

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

    DES ORGANES MOBILES peuvent L’ACIDE DE LA BATTERIE peut pro- provoquer des blessures. voquer des brûlures dans les YEUX et sur la PEAU. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Ne pas renverser la batterie. D Maintenir fermés et fixement en place les portes, D Remplacer une batterie endommagée.

  • Page 12: Principales Normes De Sécurité

    LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique D Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé...

  • Page 13: Section 2 − Definitions

    SECTION 2 − DEFINITIONS 2-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Start Engine Panel/Local Temperature Fuel Check Valve Engine Oil Battery (Engine) Clearance Read Operator’s Engine Amperes Volts Manual MIG (GMAW), Stick (SMAW) TIG (GTAW) Circuit Breaker Wire Alternating Current...

  • Page 14: Dimensions, Weights, And Operating Angles

    3-2. Dimensions, Weights, and Operating Angles Dimensions Height 33 in (838 mm) Width 18-3/4 in (476 mm) Y Do not exceed tilt angles or engine could Y Do not exceed tilt angles or engine could Depth 45-1/2 in (1156 mm) be damaged or unit could tip.

  • Page 15: Auxiliary Power Curve

    3-4. Auxiliary Power Curve The ac auxiliary power curve shows the auxiliary power available in amperes at the receptacles. AC POWER AMPERES AT 120V AC POWER AMPERES AT 240V 189 268 3-5. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated 100% Duty Cycle at 280 Amperes DC load without overheating.

  • Page 16: Volt-Ampere Curves

    3-6. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of A. CC/DC Mode the welding generator. Curves of other settings fall between the curves shown. DC AMPERES B. CV/DC Mode DC AMPERES C. CC/AC Mode AC AMPERES 189 280 / 189 282-A / 189 265 OM-4402 Page 12...

  • Page 17: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Installing Welding Generator Y Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Bolt unit down using holes pro- Movement Airflow Clearance vided in base. 18 in Y Do not lift unit from end. Y Always ground generator (460 mm) frame to vehicle frame to pre-...

  • Page 18: Activating The Dry Charge Battery (If Applicable)

    4-3. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. Eye Protection − Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum). Y Do not overfill battery cells.

  • Page 19: Connecting The Battery

    4-4. Connecting The Battery Y Connect negative (−) cable last. − Tools Needed: 3/8, 1/2 in Ref. 800 394-C / Ref. 198 912 / Ref. S-0756-D 4-5. Installing Exhaust Pipe Point exhaust pipe in desired direction. If unit is truck or trailer mounted, point pipe away from direction of travel.

  • Page 20: Selecting Weld Cable Sizes

    4-7. Selecting Weld Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) Or Less Welding (45 m) (60 m) (70 m) (90 m) (105 m) (120 m) Amperes...

  • Page 21: Adjusting Mig Weld Puddle Consistency

    4-9. Adjusting MIG Weld Puddle Consistency Y Stop engine. Stabilizer DC-Z factory connected to suit most MIG (Wire Welding) applications. To change MIG weld puddle consis- tency, proceed as follows: Remove lower front panel and side panel. Starting from center of DC-Z, the three leads 79 will be referred to as inner, middle, and outer.

  • Page 22: Section 5 − Operating Welding Generator

    SECTION 5 − OPERATING WELDING GENERATOR 5-1. Front Panel Controls DC Polarity/AC Switch runs at idle speed at no load, and weld/power To Stop: turn Engine Control switch to Off speed under load. In Run position, engine position. Y Do not switch under load. runs at weld/power speed.

  • Page 23: Remote Amperage/Voltage Control

    5-2. Remote Amperage/Voltage Control Remote 14 Receptacle RC1 Connect optional remote control to RC1 (see Section 4-8). Remote Hand Control (Optional) Remote Foot Control (Optional) Engine runs at weld/power speed whenever a device con- nected to the remote 14 recep- tacle is running.

  • Page 24: Section 6 − Operating Auxiliary Equipment

    SECTION 6 − OPERATING AUXILIARY EQUIPMENT 6-1. Auxiliary Power Receptacles And Circuit Breakers Y If unit does not have GFCI re- ceptacles, GFCI- protected extension cord. Auxiliary power decreases as weld current increases.. 240 V 50 A AC Receptacle RC1 supplies 60 Hz single-phase power at weld/power speed.

  • Page 25: Optional Auxiliary Power Receptacles

    6-2. Optional Auxiliary Power Receptacles Y If unit does not have GFCI re- ceptacles, GFCI- protected extension cord. Auxiliary power decreases as weld current increases. Combined output of all receptacles limited to 8 kVA/kW rating of the generator. GFCI Receptacle Option 120 V 15 A AC GFCI Recep- tacles GFCI2 and GFCI3 GFCI2 and GFCI3 supply 60 Hz...

  • Page 26: Section 7 − Maintenance And Troubleshooting

    SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Y Stop engine before maintaining. See Engine Manual and Maintenance Label. Ser- Recycle vice more often if used in severe conditions. engine fluids. To be done by Factory Authorized Service Agent. Wipe up spills.

  • Page 27: Maintenance Label

    7-2. Maintenance Label Follow the storage procedure in the engine owner’s manual if the unit will not be NOTE used for an extended period. OM-4402 Page 23...

  • Page 28: Servicing Air Cleaner

    7-3. Servicing Air Cleaner Y Stop engine. Y Do not run engine without air cleaner or with dirty element. Wrapper (Foam Element) Wash wrapper with soap and water solution. Allow wrapper to air dry completely. Spread 1 tablespoon SAE 30 oil evenly into wrapper.

  • Page 29: Changing Engine Oil, Oil Filter, And Fuel Filter

    7-5. Changing Engine Oil, Oil Filter, And Fuel Filter Y Stop engine and let cool. Oil Drain Valve 1/2 ID x 12 in Hose Oil Filter Change engine oil and filter accord- ing to engine manual. Y Close valve and valve cap before adding oil and run- ning engine.

  • Page 30: Adjusting Engine Speed

    7-6. Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: ± 2200 100 rpm Start engine and run until warm. Turn A/V control to max. ± 3700 50 rpm Idle Speed Adjustment Throttle Solenoid Mounting Screw...

  • Page 31: Overload Protection

    7-7. Overload Protection Y Stop engine. Tools Needed: When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized 3/8 in Service Agent. Circuit Breaker CB5 CB5 protects the 24 volt ac output to Remote 14 receptacle RC1.
  • Page 32 Trouble Remedy Low weld output. Check control settings. Place Remote Amperage/Voltage switch in Panel position, or move switch to Remote 14 position and connect remote amperage/voltage control to Remote 14 receptacle RC1. Check and clean air cleaner as necessary (see Section 7-3). Check and adjust engine speed (see Section 7-6).
  • Page 33 B. Auxiliary Power Trouble Remedy No power output. Reset circuit breakers CB1, CB2, CB3 and/or CB4 (see Section 6-1). Check fuse F1, and replace if necessary (see Section 7-7). Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2. Low power output.

  • Page 34: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Welding Generator OM-4402 Page 30...
  • Page 35 199 560 OM-4402 Page 31...

  • Page 36: Section 9 − Auxiliary Power Guidelines

    SECTION 9 − AUXILIARY POWER GUIDELINES 9-1. Selecting Equipment Auxiliary Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Be sure equipment has this symbol and/or wording. aux_pwr 2/99 − Ref. ST-159 730 / ST-800 577 9-2.
  • Page 37 9-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE 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. Use ground device as stated in electrical codes.
  • Page 38 9-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 39 9-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
  • Page 40 9-8. Power Required To Start Motor Motor Start Code AC MOTOR Running Amperage VOLTS AMPS Motor HP CODE Motor Voltage PHASE 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 41 9-10. 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 Customer-supplied equipment is required if greater than the branch overcurrent generator is to supply standby power during protection.
  • Page 42 9-11. 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. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68)

  • Page 43: Section 10 − Parts List

    SECTION 10 − PARTS LIST Hardware is common and not available unless listed. ST-802 048-D Figure 10-1. Main Assembly OM-4402 Page 39...
  • Page 44 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Main Assembly ....182 367 PANEL, right side ..........♦185 352 .
  • Page 45 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Main Assembly (Continued) ... . . 174 824 CONNECTOR & PINS ..........
  • Page 46 Item Dia. Part Mkgs. Description Quantity Figure 10-2. Panel, Front w/Components (Fig 10-1 Item 54) ....187 593 PANEL, front ........... .
  • Page 47 Item Part Description Quantity Figure 10-3. Generator (Fig 10-1 Item 24) ....+186 238 STATOR ............
  • Page 49 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY − Subject to the terms and conditions Induction Heating Coils and Blankets below, Miller Electric Mfg.

  • Page 50: Options And Accessories

    Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories To locate a distributor or service agency near you, call 1-800-4-A-Miller or visit our Personal Safety Equipment website at www.MillerWelds.com Service and Repair Miller Electric Mfg. Co.

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