Instruction/ maintenance manual of the product Metro 250D Miller Electric
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Processes OM-402B April 1997 Eff. w/Serial Number KH383240 Gas Tungsten Arc (TIG) W elding Shielded Metal Arc (Stick) W elding Flux Cored Arc W elding Description Engine Driven Welding Generator With Optional Equipment: Metro 250D V isit our website at www.
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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
Descripti on Feat ure s NEW! W arranty extended to 3 years (engine warranted by engine manufacturer) V ersatile weld output for DC Stick and DC TIG welding Stepless amperage control for pr.
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1 OM-402 1 . Safety Precauti ons − Read Before Using 1.1 Symbol Usage OM-402B -4/97, safety_rom 4/97 Means Warning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Marks a special safety message.
2 OM-402 W elding on closed containers, such as tanks, drums, o r pipes, can cause them to blow up. Sparks c a n fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.
3 OM-402 MOVING P ARTS can cause injury . Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary .
4 OM-402 H. F . RADIA TION can cause interference. High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation.
5 OM-402 1 . C onsi gn es de sécurité − l ire a vant u t ilisation 1.1 Signification des symboles OM-402B - 4/97, safety_rom_fre 4/97 Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.
6 OM-402 Le soudage ef fectué 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.
7 OM-402 DES ORGANES MOBILES peuvent provoquer des blessures. Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.
8 OM-402 LES CHARGES ÉLECTROSTA TIQUES peuvent endommager les circuits imprimés. Établir l a connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. Utiliser des pochettes et des boîtes antistatiques pour stocker , déplacer ou expédier des cartes de circuits imprimes.
9 OM-402 2 . Defini tions 2.1 Symbols and Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Glow Plug T emperature Fuel Engine Oil 14 Remote 14 Panel/Local .
10 OM-402 3/96 2.2 General Precautionary Label 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 S-176 105-A + 2 2.1 2.2 + 5 + 7 7.1 7.2 2.3 + 6 6.1 6.2 6.3 + = A. W arning! 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.
11 OM-402 2.3 Battery Charging Label 3/96 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Do not smoke and keep matches and flames away from battery . 3 Sparks can cause battery gases to explode. Battery explosion can blind and injure.
12 OM-402 2.5 Hot Muffler Label 3/96 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Hot muf fler and exhaust pipes can cause severe burns. Do not touch hot muf fler or pipes. 1 S-176 230 2 2.6 Diesel Fuel Label 3/96 1 W arning! W atch Out! There are possible hazards as shown by the symbols.
13 OM-402 2.7 Falling Equipment Label S-176 104 3/96 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Falling equipment can cause serious injury and damage. 3 Use lifting eye to lift or move unit only . Use proper equipment when lifting.
14 OM-402 2.9 Do Not Use Ether Label 3/96 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Ether will damage engine. Do not use ether as a starting aid. 3 Read Owner ’ s Manual. 4 Use glow plugs for 10 − 25 seconds to aid starting in cold weather .
15 OM-402 3 . Specifi cations 3.1 W eld, Power , and Engine Specifications Rated W elding Output Amperage Range Maximum Open-Circuit V oltage DC Auxiliary Power Rating Engine Fuel Capacity A verage So.
16 OM-402 3.4 Fuel Consumption SA-180 263-A 3.5 Duty Cycle and Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.
17 OM-402 3.6 AC Auxiliary Power Curve SA-180 260 The auxiliary power curve shows the auxiliary power in amperes available at the receptacles. 4 . Installation 4.
18 OM-402 4.2 Connecting Battery and Installing Exhaust Pipe ST-801 079-A / Ref. ST -175 918-C 7/16, 1/2 in + − Connect negative ( − ) cable last. T ools Needed: Stop engine. Installation of exhaust pipe is optional. 4.3 Engine Prestart Checks Ref.
19 OM-402 4.4 Connecting to Weld Output T erminals Ref. ST-158 936-D / Ref. ST -175 918-C 1 Positive (+) W eld Output T erminal 2 Negative ( − ) W eld Output T erminal For Direct Current Electrode Positi- ve (DCEP), connect work cable to Negative ( − ) terminal and electrode cable (Stick) or torch cable (TIG) t o Positive (+) terminal.
20 OM-402 4.6 Remote 14 Receptacle RC1 Information Ref. S T -158 9 3 Socket* Socket Information A 24 volt ac with respect to socket G. Protected by circuit breaker CB5. B Contact closure to A completes 24 volt ac contactor control circuit. AJ B K I G Circuit common for 24 volt ac circuit.
21 OM-402 5 . Op eratin g th e Weld ing Generator 5.1 Front Panel Controls Ref. ST-175 918-C 9 Heavy loading during first 50 hours will damage engine.
22 OM-402 5.2 Remote Amperage and Contactor Control W eld output terminals are energized when Output (Contactor) Control switch is On and engine is running. 1 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.
23 OM-402 6 . Oper ating Auxiliary Equipment 6.1 Auxiliary Power Receptacles Place Engine Control switch in Run position to maintain weld/power speed under light auxiliary power loads. Press button to reset circuit breaker . If a circuit breaker continues to open, contact a Factory Authorized Service Agent.
24 OM-402 7 . Mainte nance & Troubleshoot ing 7.1 Routine Maintenance Recycle engine fluids. Stop engine before maintaining. Se e also Engine Manual and Maintenance Label. Service engine more often if used in severe conditions. 8 h Wipe up spills.
25 OM-402 6-2. Maintenance Label S-157 812-E 20W 30 50 40 API CD-MIL L 2104D, SF/CD, CC/CD 2.4 qt (2.3 L) MILLER 066 702 Deutz 77-175-24 MILLER 066 1 1 3 1 1.8 gal (44.6 l ) 100 Hrs. + 12 V BCI 58 430 A @ 0 ° F (-18 ° C) Deutz 77-656-19 72 ° F (20 ° C) 0.
26 OM-402 7.3 Changing Engine Oil and Oil Filter Ref. ST-159 219-D / Ref. ST -159 215-E / Ref. ST -175 918-C / Ref. S-0842 T ools Needed: Stop engine.
27 OM-402 7.4 Changing Fuel Filters Stop engine and let cool. 1 Secondary Fuel Filter Remove filter . Apply thin film of oil to gasket on new filter . Install filter . 2 Primary Fuel Filter 3 Fuel Line Remove filter . Inspect all fuel lines and replace if cracked or worn.
28 OM-402 7.6 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 T urn Engine Control switch to Run/ Idle position.
29 OM-402 7.7 Overload Protection 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. W eld And Auxiliary Power Circuits 1 Fuse F2 F2 protects battery excitation circuit.
30 OM-402 7.8 Servicing Optional Spark Arrestor ST-801 154-B / Ref. ST -175 918-C Stop engine and let cool. 1 Spark Arrestor 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole.
31 OM-402 T rouble Remedy Erratic weld output. Clean and tighten weld output connections inside and outside unit. Use dry , properly-stored electrodes.
32 OM-402 T rouble Remedy 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 .
33 OM-402 Notes.
34 OM-402 8 . Electrical Diagram 8.1 Circuit Diagram for Welding Generator.
35 OM-402 SC-181 758.
36 OM-402 9. Run-In Pr ocedur e 9.1 W etstacking runin2 12/96 Heavy loading during first 5 0 hours will damage engine. Keep load less than 225A (weld) or 7 kV A (power) for first 5 0 hours.
37 OM-402 9.2 Run-In Procedure Using Load Bank S-0683 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. 1 Load Bank T urn all load bank switches Of f. If needed, connect load bank to 1 15 volts ac wall receptacle or genera- tor auxiliary power receptacle.
38 OM-402 9.3 Run-In Procedure Using Resistance Grid S-0684 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/ grid. Keep exhaust and pipe away from flammables. 1 Resistance Grid Use grid sized for generator rated output.
39 OM-402 10 . Auxiliary Power Guidelines 10.1 Selecting Equipment aux_pwr 12/96 − Ref. ST-159 730 / ST -800 577 1 Auxiliary Power Receptacles − Neutral Bonded T o Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated Equipment OR 2 Be sure equipment has this symbol and/or wording.
40 OM-402 10.3 Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
41 OM-402 10.5 Approximate Power Requirements for Industrial Motors Industrial Motors Rating Sta rtin g W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700.
42 OM-402 10.7 Approximate Power Requirements for Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 50.
43 OM-402 10.8 Power Required to Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage.
44 OM-402 10.10 T ypical Connections to Supply Standby Power S-0405-A 1 Power Company Service Meter 2 Main and Branch Overcurrent Protection 3 Double-Pole, Double-Throw T ransfer Switch Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection.
45 OM-402 10.1 1 Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
46 OM-402 1 1. P a r t s L i s t 1 1.1 Main Assembly 1 2 3 4 5 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 84 85 86 87 88 89 90 91 92 93 96 94 6 7 Fig 1 1 -2 Fig 1 1 -4 95 83 Hardware is common and not available unless listed.
47 OM-402 30 ST-801 488-A 31 32 33 34 35 36 37 38 39 40 43 45 47 48 49 50 51 52 53 54 56 Fig 1 1 -3 57 58 59 60 62 63 65 66 67 68 69 70 71 72 73 74 75 76 77 78 80 79 81 61 82 42 64 55 41 44 46.
48 OM-402 1 1.1 (Continued) Description Part No. Dia. Mkgs. Item No. Quantity 1 +163 828 P ANEL, side LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 164 507 P ANEL, side LH rear 1 .
49 OM-402 1 1.1 (Continued) Description Part No. Dia. Mkgs. Item No. Quantity 41 173 931 PIPE, exhaust elbow 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 167 313 LA TCH, elastic draw 2 .
50 OM-402 1 1.1 (Continued) Description Part No. Dia. Mkgs. Item No. Quantity 88 162 515 RECTIFIER, si diode (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1,3 048 420 CAP ACITOR, cer disc .
51 OM-402 1 1.2 (Continued) ST-801 515-A 1 2 3 4 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Hardware is common and not available unless listed. Description Part No. Dia. Mkgs. Item No. Quantity 13 CB5 083 432 CIRCUIT BREAKER, man reset 1P 10A 250V AC 1 .
52 OM-402 1 1.3 Generator (Fig 1 1.1 Item 56) 1 ST-801 289A 2 4 5 3 6 7 8 9 10 11 16 15 14 13 12 Hardware is common and not available unless listed. Description Part No. Item No. Quantity 1 166 770 STUD, stl .375-16 x 19.750 1 . . . . . . . . . . .
53 OM-402 ST-801 288 1 2 3 4 4 5 6 7 8 9 10 11 12 13 8 14 15 16 1 1.4 Control Box w/Components (Fig 1 1.1 Item 86) Hardware is common and not available unless listed. Description Part No. Dia. Mkgs. Item No. Quantity 1 D1,5 135 184 DIODE BOARD 2 .
54 OM-402 Notes.
Notes.
56 OM-402 Notes.
Notes.
58 OM-303 12 . Options and Accessories 12.1 Metro 250D WELD METERS − DC AMP & VOL T (#042 947 Field ) Machine is prewired for easy installation of field kit. ST ARTING AID KITS (#043 139 Field ) Improve starting in cold weather by adding air intake manifold glow plug.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor .
PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Compa ny 1635 West S pencer Street Applet on, WI 54914 USA International He adquarte rs − US .
An important point after buying a device Miller Electric Metro 250D (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric Metro 250D yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric Metro 250D - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric Metro 250D you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric Metro 250D will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric Metro 250D, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric Metro 250D.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric Metro 250D. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric Metro 250D along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
