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OM-228 042B 2007 −09
Processes Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Engine Driven Welding Power Source/
Wire Feeder/Generator
Renegade 180
File: Engine Drive
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Engine Hazards . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 8-1. Power Source Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 8-2. Gun Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 8-3. Welding Power Source O
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 −04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible This group
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Do not weld on closed containers such as tanks, drums, or pipes, FUMES AND GASES can be hazardous. unless they are properly prepared according to AWS F4.1 (see Safety Standards). Welding produces fumes and gases. Breathing these Do not weld where the atmosphere may contain flammable dust, fumes and gases can be hazardous to your health. gas, or liquid vapors (such as gasoline). Keep your head out of the fumes. Do not breathe the fumes. Connect work cable to the work as close to the weldi
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1-3. Engine Hazards STEAM AND HOT COOLANT can burn. BATTERY EXPLOSION can BLIND. If possible, check coolant level when engine is Always wear a face shield, rubber gloves, and cold to avoid scalding. protective clothing when working on a battery. Always check coolant level at overflow tank, if Stop engine before disconnecting or connect- present on unit, instead of radiator (unless told ing battery cables or servicing battery. otherwise in maintenance section or engine Do not allow tool
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HOT METAL from air arc cutting and READ INSTRUCTIONS. gouging can cause fire or explosion. Read Owner’s Manual before using or servic- Do not cut or gouge near flammables. ing unit. Watch for fire; keep extinguisher nearby. Stop engine and release air pressure before servicing. Use only genuine replacement parts from the HOT PARTS can cause burns and injury. manufacturer. Do not touch hot compressor or air system parts. Let system cool down before touching or ser- vicing. 1-5. Addi
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H.F. RADIATION can cause interference. ARC WELDING can cause interference. High-frequency (H.F.) can interfere with radio Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as micro- communications equipment. processors, computers, and computer-driven equipment such as robots. Have only qualified persons familiar with electronic equipment perform this installation. Be sure all equipment in the welding area is electrom
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_2007 −04fre 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 Indique des instructions spécifiques. l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui s
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Une tension DC importante subsiste à l’intérieur LES RAYONS DE L’ARC peuvent pro des onduleurs après avoir coupé l’alimentation. voquer des brûlures dans les yeux e Couper l’alimentation du poste et décharger les condensateurs sur la peau. d’entrée comme indiqué dans la Section Maintenance avant de Le rayonnement de l’arc du procédé de soudage toucher des composants. génère des rayons visibles et invisibles intense (ultraviolets et infrarouges) susceptibles de provoquer des brûlure DES PIÈCES
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Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et Protéger les bouteilles de gaz comprimé d’une chaleur excessive, NFPA 51B pour les travaux à chaud et avoir de la surveillance et un des chocs mécaniques, des dommages physiques, du laitier, des extincteur à proximité. flammes ouvertes, des étincelles et des arcs. Placer les bouteilles debout en les fixant dans un support station- LE BRUIT peut affecter l’ouïe. naire ou dans un porte-bouteilles pour les empêcher de tomber ou de se
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Dévisser le bouchon légèrement et laisser la vapeur s’échapper LA CHALEUR DU MOTEUR peut pro- avant d’enlever le bouchon. voquer un incendie. L’utilisation d’un groupe autonome Ne pas placer l’appareil sur, au-dessus ou à à l’intérieur PEUT VOUS TUER EN proximité de surfaces inflammables. QUELQUES MINUTES. Tenir à distance les produits inflammables de l’échappement. Les fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore. LES ÉTINCELLES À L
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UNE REMORQUE QUI BASCULE peut LE SURCHAUFFEMENT peut endom- entraîner des blessures. mager le moteur électrique. Utiliser les supports de la remorque ou des Arrêter ou déconnecter l’équipement avant de blocs pour soutenir le poids. démarrer ou d’arrêter le moteur. Installer convenablement le poste sur la remor- Ne pas laisser tourner le moteur trop lentement sous risque d’en- que comme indiqué dans le manuel s’y rappor- dommager le moteur électrique à cause d’une tension et d’une fré- ta
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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. provoquent des cancers et des malformations congénitales (Code de santé
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Complete Parts List available at www. MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Read Operator’s Engine Choke Amperes Volts Manual A V Engine Oil Fuel Circuit Protector Engine Alternating Current Positive Negative Output (AC) Direct Current Protective Earth Hours Time (DC) (Ground) h Single-Phase 230 Off Temperature Input Input Volt Power GMAW Gun Shielding Gas Wire Speed Over Temperature Trigger Input Spool Gun SECTION 4 − SPECIFICATIONS 4-1. Description This unit is an e
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Complete Parts List available at www. MillerWelds.com 4-3. Gun Specifications Air-Cooled Welding Guns For GMAW And FCAW Welding Using gasless flux cored wire reduces gun duty cycle. M-15 Feeds .023 To .045 in. (0.6 To 1.1 mm) Hard Or Flux Cored Wires .045 in. (1.1 mm) wire requires liner change to MILLER Part No. 194012 in addition to contact tip change Duty Cycle Rating: 100%: 150 A With CO Shielding Gas; 120 A With Mixed Gases 2 60%: 200 A With CO Shielding Gas; 150 A With Mixed Gases 2 We
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Complete Parts List available at www. MillerWelds.com 4-6. Fuel Consumption 1.00 0.80 0.60 0.40 0.20 0.00 01 23 45 6 Auxiliary Power Kw At 100% Duty Cycle 233 244 4-7. Power Source Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle 300 can damage unit and void warranty. 250 200 150 135 105 80 60 50 10 15 20 25 30 40 50 60 70 80 100 % Duty Cycle 30% duty cycle at 135 amps, 60 Hz 20% duty cycle at 130 amps, 50
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Complete Parts List available at www. MillerWelds.com 4-8. Gun Duty Cycle And Overheating See Section 4-3. Specifications for amperage rating and duty cycle. Duty Cycle is percentage of 10 minutes that unit can weld at rated 60%dutycycle 100%dutycycle load without overheating. NOTICE − Exceeding duty cycle can damage unit and void warranty. 6 Minutes Welding 4 Minutes Resting Continuous Welding Overheating 0 A or V 15 OR Reduce Duty Cycle Minutes sduty1 5/95 4-9. Generator Power Curve The ac g
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Complete Parts List available at www. MillerWelds.com SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Airflow Clearance Movement 18 in 18 in (460 mm) (460 mm) 18 in (460 mm) Shown with standard running gear and optional cylinder rack. 18 in 18 in (460 mm) (460 mm) Location Do not install unit where air flow is restricted or engine may overheat. Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. Always grou
