Table of Contents
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Trailblazer 325
Trailblazer 275
OM-249 795D
2013−02
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Pulse 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
R
File: Engine Drive
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Table of Contents
Troubleshooting
Related Manuals for Miller Trailblazer 325
Summary of Contents for Miller Trailblazer 325
- Page 1 Stick (SMAW) Welding TIG (GTAW) Welding Pulse 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 325 Trailblazer 275 File: Engine Drive Visit our website at www.MillerWelds.com...
- Page 2 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ....... . . 1-1. - Page 4 TABLE OF CONTENTS SECTION 7 − OPERATING AUXILIARY EQUIPMENT ..........7-1.
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Page 5: Section 1 − Safety Precautions − Read Before Using
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2011−10 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. - Page 6 D Do not weld on containers that have held combustibles, or on FUMES AND GASES can be hazardous. closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Welding produces fumes and gases. Breathing these Safety Standards).
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Page 7: Engine Hazards
1-3. Engine Hazards EXHAUST SPARKS can cause fire. BATTERY EXPLOSION can injure. D Do not let engine exhaust sparks cause fire. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Use approved engine exhaust spark arrestor in required areas —... -
Page 8: Additional Symbols For Installation, Operation, And Maintenance
HOT METAL from air arc cutting and MOVING PARTS can injure. gouging can cause fire or explosion. D Keep away from moving parts such as fans, D Do not cut or gouge near flammables. belts and rotors. D Watch for fire; keep extinguisher nearby. D Keep all doors, panels, covers, and guards closed and securely in place. - Page 9 BATTERY CHARGING OUTPUT and BATTERY STATIC (ESD) can damage PC boards. EXPLOSION can injure. D Put on grounded wrist strap BEFORE handling Battery charging not present on all models. boards or parts. D Use proper static-proof bags and boxes to D Always wear a face shield, rubber gloves, and protective store, move, or ship PC boards.
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Page 10: California Proposition 65 Warnings
1-6. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &... -
Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2011−10 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. - Page 12 Il reste une TENSION DC NON NÉGLIGEABLE dans les LES RAYONS DE L’ARC peuvent sources de soudage onduleur UNE FOIS le moteur coupé. provoquer des brûlures dans les yeux et sur la peau. D Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué...
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Page 13: Dangers Existant En Relation Avec Le Moteur
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, LE BRUIT peut affecter l’ouïe. des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. Le bruit des processus et des équipements peut D Placer les bouteilles debout en les fixant dans un support station- affecter l’ouïe. -
Page 14: Dangers Liés À L'air Comprimé
LA VAPEUR ET LE LIQUIDE DE L’ACIDE DE LA BATTERIE peut pro- REFROIDISSEMENT CHAUD peuvent voquer des brûlures dans les YEUX et provoquer des brûlures. sur la PEAU. D Il est préférable de vérifier le liquide de refroi- D Ne pas renverser la batterie. dissement une fois le moteur refroidi pour éviter D Remplacer une batterie endommagée. -
Page 15: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
détendre la pression et s’assurer que le circuit d’air ne peut être L’INHALATION D’AIR COMPRIMÉ risque mis sous pression par inadvertance. de provoquer des blessures ou même D Demander seulement à un personnel qualifié d’enlever la mort. les dispositifs de sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de dépannage. - Page 16 LA SORTIE DE RECHARGE et L’EXPLO- LES CHARGES ÉLECTROSTATI- SION BATTERIE peuvent QUES peuvent endommager les provoquer des blessures. circuits imprimés. D Établir la connexion avec la barrette de terre La recharge de batterie n’existe pas sur tous les avant de manipuler des cartes ou des pièces. modèles.
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Page 17: Proposition Californienne 65 Avertissements
2-6. Proposition californienne 65 Avertissements Pour les moteurs à essence : Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques Les gaz d’échappement des moteurs contiennent des pro- dont l’État de Californie reconnaît qu’ils provoquent des mal- duits chimiques dont l’État de Californie reconnaît qu’ils formations congénitales et, dans certains cas, des cancers. -
Page 18: Section 3 − Definitions
Complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Never use generator inside a home or garage, even if doors and win- dows are open. -
Page 19: Section 4 − Specifications
Complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Specifications Rated Weld Maximum Welding Generator Fuel Welding Output Open-Circuit Engine Mode Power Rating Capacity Output Range Voltage Kohler CH730 275 Model: 275 A, 28 V, 100% 30 − 275 A Air-Cooled, CC/DC Duty Cycle... -
Page 20: Dimensions, Weights, And Operating Angles
Complete Parts List is available at www.MillerWelds.com 4-2. Dimensions, Weights, And Operating Angles Do not exceed tilt angles or engine could be damaged or unit could tip. ° Do not move or operate unit where it could tip. ° ° Weight: 460 lb (209 kg) w/o fuel 533 lb (242 kg) w/fuel °... -
Page 21: Fuel Consumption Curves
Complete Parts List is available at www.MillerWelds.com 4-3. Fuel Consumption Curves On a typical job using 1/8 in. 7018 electrodes (125 amps, 20% duty cycle), expect about 20 hours of op- eration with carbureted engine (24 hours with EFI engine). Welding at 150 amps at 40% duty cycle uses about 3/4 gallon of fuel per hour. -
Page 22: Stick Volt-Ampere Curves
Complete Parts List is available at www.MillerWelds.com 4-4. Stick Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. CC/DC XX10 Electrode 30 A 150 A Soft 25 150 A 150 A Stiff 25 325 A AMPERES CC/DC XX18 Electrode... -
Page 23: Mig Volt-Ampere Curves
Complete Parts List is available at www.MillerWelds.com 4-5. MIG Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. 35 Volts 25 Volts 13 Volts AMPERES 257 137 4-6. TIG Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of... -
Page 24: Duty Cycle
Complete Parts List is available at www.MillerWelds.com 4-7. Duty Cycle Duty cycle is the percentage of 10 100%dutycycle minutes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle can damage unit and void warranty. Continuous Welding 254 868-A Notes... -
Page 25: Section 5 − Installation
Complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Location The serial number for this product is located on the front. The rating information for this product is located on the back. Use rating label to determine rated output. -
Page 26: Grounding Generator To Truck Or Trailer Frame
Complete Parts List is available at www.MillerWelds.com 5-3. Grounding Generator To Truck Or Trailer Frame GND/PE rot_grnd2 2012−03 − 800 652-D frame. Always connect a ground Equipment Grounding Terminal (On Always ground generator frame to wire from the generator equipment Front Panel) vehicle frame to prevent electric grounding terminal to bare metal on... -
Page 27: Engine Prestart Checks
Complete Parts List is available at www.MillerWelds.com 5-5. Engine Prestart Checks 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 en- gine manual. This unit has a low oil pressure Full shutdown switch. -
Page 28: Connecting Or Replacing The Battery
Complete Parts List is available at www.MillerWelds.com 5-6. Connecting Or Replacing The Battery Connect negative (−) battery cable last To connect battery, open side access doors. Battery Holddown To change battery, remove rear pan- el with baffle and battery holddown. Be sure battery cables and fuel tank vent hose are not pinched when in- stalling battery and replacing rear... -
Page 29: Weld Output Terminals
Complete Parts List is available at www.MillerWelds.com 5-8. Weld Output Terminals Stop engine. Positive (+) Weld Output Terminal Stick Negative (−) Weld Output Terminal Wire/TIG/Gouge Negative (−) Weld Output Terminal For MIG welding, connect work cable to Negative (−) terminal and wire feeder cable to Positive (+) terminal. -
Page 30: Connecting To Weld Output Terminals
**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. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-J 2011−07 OM-249 795 Page 26... -
Page 31: Remote Receptacle Information
Complete Parts List is available at www.MillerWelds.com 5-11. Remote Receptacle Information Socket* Socket Information 24 volts ac. Protected by supplementary protector C L N CB4. 24 VOLTS AC Contact closure to A completes 24 volt AC con- tactor control circuit and keeps engine at Run speed in all Wire modes. -
Page 32: Section 6 − Operating Welding Generator
Complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls (See Section 6-2) 248 009-A / 251 160-A OM-249 795 Page 28... -
Page 33: Description Of Front Panel Controls (See Section 6-1)
Complete Parts List is available at www.MillerWelds.com 6-2. Description Of Front Panel Controls (See Section 6-1) Process/Contactor Switch Wire position, use control to adjust voltage. To Start: pull out choke (if equipped) and When a remote voltage/amperage control is turn Engine Control switch to Start position. See Section 6-4 for Process/Contactor connected to Remote receptacle RC4, con- Release switch when engine starts. -
Page 34: Cold Weather Engine Operation
Complete Parts List is available at www.MillerWelds.com 6-3. Cold Weather Engine Operation Engine Control Switch Carburetor Icing Infrequently Loaded Carburetor icing causes the unit to drop below the normal idle speed and then stall. This condition occurs when the temperature is near freezing and the rela- tive humidity is high. -
Page 35: Process/Contactor Switch, Engine Auto Speed, And Arc Control
Complete Parts List is available at www.MillerWelds.com 6-4. Process/Contactor Switch, Engine Auto Speed, And Arc Control SOFT 250 916-A / 248 009-A Process/Contactor Switch For Stick applications, the Arc control var- For TIG, based on preset, unit goes to ies additional amperage during short arc speed appropriate for load at arc initiation. - Page 36 Complete Parts List is available at www.MillerWelds.com Table 6-1. Process/Contactor Switch And Arc Control Settings Arc Control is not active when the Process/Contactor switch is in the following positions: Output On / Wire / Flux Core Output On / Stick / Gouge Remote On/Off / Wire / Flux Core TIG processes also do not have arc control but process information is included in the table.
- Page 37 Complete Parts List is available at www.MillerWelds.com Lift Arc start. Optimum for flat joint to end weld with crater fill, allow- Active ing for addition of filler, without loss of shielding gas Lift Arc start. Preset maximum current. Unit automatically pulses Active maximum output 40% of the time and 25% of peak output for 60% of the time based on 100 pulses per second.
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Page 38: Stick Start Procedure − Scratch Start Technique
Complete Parts List is available at www.MillerWelds.com 6-5. Stick Start Procedure − Scratch Start Technique With Stick selected, start arc as follows: Electrode Workpiece Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. -
Page 39: Remote Voltage/Amperage Control
Complete Parts List is available at www.MillerWelds.com 6-7. Remote Voltage/Amperage Control Remote Receptacle RC4 Connect optional remote voltage/ amperage (V/A) control to RC4 (see Section 5-11). Process/Contactor Switch With remote control connected, weld output in Stick or TIG is deter- mined by a combination of front panel and remote control voltage/ amperage settings. -
Page 40: Section 7 − Operating Auxiliary Equipment
Complete Parts List is available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles And Supplementary Protectors Ref. 248 009 RC1 supplies 60 Hz single-phase power at Supplementary Protector CB3 Use GFCI protection when operat- weld/power speed. Maximum output is ing auxiliary equipment. -
Page 41: Gfci Receptacle Information, Resetting And Testing
Complete Parts List is available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting And Testing Test and reset GFCI only at Run speed. RotGFCI1 2012−05 If a ground fault is detected, the GFCI Reset Check for damaged or wet tools, cords, Use GFCI protection when operat- button pops out, and the circuit opens to plugs, etc. -
Page 42: Optional Excel Power
Complete Parts List is available at www.MillerWelds.com 7-3. Optional Excel Power Excel power option provides gener- ator power at idle speed and while welding. This allows most job site tools to operate properly at engine idle speed. Use GFCI protection when operating auxiliary equip- ment. -
Page 43: Wiring Instructions For Optional 240 Volt, Single-Phase Plug (Nema 14-50P)
Complete Parts List is available at www.MillerWelds.com 7-5. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram. Plug Wired for 120/240 V, 3-Wire Load When wired for 120 V loads, each duplex receptacle shares a load... -
Page 44: Section 8 − Maintenance & Troubleshooting
Complete Parts List is available at www.MillerWelds.com SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Maintenance Label OM-249 795 Page 40... -
Page 45: Routine Maintenance
Complete Parts List is available at www.MillerWelds.com 8-2. Routine Maintenance Also see Voltmeter/Ammeter displays to assist in scheduling maintenance (see Section 6-1). The Voltmeter and Ammeter display total engine operating hours at start-up. Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period Stop engine before maintaining. -
Page 46: Servicing Air Cleaner
Complete Parts List is available at www.MillerWelds.com 8-4. Servicing Air Cleaner Stop engine. NOTICE − Do not run engine with- out air cleaner or with dirty element. Precleaner Wash precleaner with soap and wa- ter solution. Allow precleaner to air dry completely. -
Page 47: Changing Engine Oil, Oil Filter, And Fuel Filter
Complete Parts List is available at www.MillerWelds.com 8-6. Changing Engine Oil, Oil Filter, and Fuel Filter Stop engine and let cool. Oil Drain Valve Change engine oil and filter accord- ing to engine owner’s manual. NOTICE − Close valve and valve cap before adding oil and running engine. -
Page 48: Overload Protection
Complete Parts List is available at www.MillerWelds.com 8-7. Overload Protection Stop engine. Open left side door. When a supplementary protec- tor or fuse opens, it usually in- dicates a more serious prob- lem exists. Contact a Factory Authorized Service Agent. Supplementary Protector CB4 and Circuit Breaker CB5 are located on the engine baffle be-... -
Page 49: Welding Troubleshooting
Complete Parts List is available at www.MillerWelds.com 8-9. Welding Troubleshooting Trouble Remedy 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 voltage/amperage control settings (see Sections 5-11 and 6-1). Check and secure connections to Remote receptacle RC4 (see Sections 5-11). -
Page 50: Generator Power Troubleshooting
Complete Parts List is available at www.MillerWelds.com Trouble Remedy Wandering arc − poor control of arc Reduce gas flow rate. direction. Select proper size tungsten. Properly prepare tungsten. Tungsten electrode oxidizing and not Shield weld zone from drafts. remaining bright after conclusion of weld. - Page 51 Complete Parts List is available at www.MillerWelds.com Trouble Remedy Engine starts but stops when Engine Check oil level (see Section 5-5). Low oil pressure shutdown stops engine if oil pressure is too low. Control switch returns to Auto Speed position. Engine starts but stops when Engine Use correct grade oil for operating temperature.
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Page 52: Section 9 − Parts List
Complete Parts List is available at www.MillerWelds.com SECTION 9 − PARTS LIST A complete Parts List is available on-line at www.MillerWelds.com. 9-1. Recommended Spare Parts Dia. Part Mkgs. Description Quantity Recommended Spare Parts ... . -
Page 53: Section 10 − Electrical Diagrams
SECTION 10 − ELECTRICAL DIAGRAMS 249 792-E Figure 10-1. Circuit Diagram For 275 Model Welding Generator OM-249 795 Page 49... - Page 54 247 672-E Figure 10-2. Circuit Diagram For 325 Model Welding Generator OM-249 795 Page 50...
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Page 55: 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 Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment... -
Page 56: Grounding When Supplying Building Systems
11-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. GND/PE Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. - Page 57 11-5. 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 58 11-7. 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 59 11-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
- Page 60 11-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install, ground, and operate this equipment ac- cording to its Owner’s Manu- Fused Welding Utility al and national, state, and lo- Disconnect Electrical Generator...
- Page 61 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten- sion cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts)
- Page 62 Notes OM-249 795 Page 58...
- Page 63 Effective January 1, 2013 (Equipment with a serial number preface of MD or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
- Page 64 Contact the Delivering Carrier to: 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2013 Miller Electric Mfg. Co. 2013−01...