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Miller Electric Renegade 180 manual

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Table of contents for the manual

  • Page 1

    Processes OM-228 042B 2007 − 09 Rene gade 180 Processes Description MIG (GMA W ) W elding Flux Cored (FCA W ) W elding Engine Driven Welding Power Source/ Wire Feeder/Generator Visit our website at www.MillerWelds.com File: Engine Drive t[...]

  • Page 2

    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 specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS SECTION 8 − MAINTENANCE 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Power Source Routine Maintenance 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Gun Routine Maintenance 32[...]

  • Page 5

    OM-228 042 Page 1 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 not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols [...]

  • Page 6

    OM-228 042 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous.  Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.  If ventilation [...]

  • Page 7

    OM-228 042 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can BLIND.  Always wear a face shield, rubber gloves, and protective clothing when working on a battery .  Stop engine before disconnecting or connect- ing battery cables or servicing battery .  Do not allow tools to cause sparks when working on a battery .  Do not use welder to [...]

  • Page 8

    OM-228 042 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion.  Do not cut or gouge near flammables.  W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury .  Do not touch hot compressor or air system parts.  Let system cool down before touching or ser- vicing. READ INSTRUCTIONS. ?[...]

  • Page 9

    OM-228 042 Page 5 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.  The user is responsible for having a qualified electrician promptly co[...]

  • Page 10

    OM-228 042 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION 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 l’évite pas peut donner la mort ou des [...]

  • Page 11

    OM-228 042 Page 7 Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation.  Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.  Ne pas[...]

  • Page 12

    OM-228 042 Page 8  Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et N FPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut affe c l’ouïe.  Porter des protections approuvés pour les or e les si le niveau sono[...]

  • Page 13

    OM-228 042 Page 9  Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES.  Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore.  JAMAIS utiliser [...]

  • Page 14

    OM-228 042 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant d e démarrer ou d’arrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager le moteur électrique à cause d’une tension et d’une fré - quence trop faibles.  N e pas[...]

  • Page 15

    OM-228 042 Page 1 1 2-6. P r oposition californienne 65 A vertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité [...]

  • Page 16

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 12 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Engine Choke Read Operator ’s Manual A Amperes V V olts Engine Oil Fuel Circuit Protector Engine Positive Negative Alternating Current (AC) Output h Hours Direct Current (DC) T ime Protective Earth (Ground) Of f T emper[...]

  • Page 17

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 13 4-3. Gun Specifications Air-Cooled W elding Guns For GMA W And FCAW W elding  Using gasless flux cored wire reduces gun duty cycle. Ref. 800 797-D M-15 Feeds .023 T o .045 in. (0.6 T o 1.1 mm) Hard Or Flux Cored Wires .045 in. (1.1 mm) wire requires liner change to MI[...]

  • Page 18

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 14 4-6. Fuel Consumption 233 244 Auxiliary Power Kw At 100% Duty Cycle US Gal./Hr . 01 23 45 6 0.00 0.20 0.40 0.60 0.80 1.00 4-7. Power Source Duty Cycle 230 343-A Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. NOTICE − Ex[...]

  • Page 19

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 15 See Section 4-3. Specifications for amperage rating and duty cycle. Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle ca n damage unit and void warranty . Overheating 0 15 A or V OR Reduce Duty Cy[...]

  • Page 20

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 16 SECTION 5 − INST ALLA TION Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. 1 Metal V ehicle Frame 2 Equipment Grounding T erminal 3 Grounding Cable Bed liners, shipping skids, an d some running gear insu- late [...]

  • Page 21

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 17 5-2. Grounding Generator When Supplying Building Systems GND/PE 1 2 2 3 800 576-B Ground generator to sys- tem earth ground if supply- ing power to a premises (home, shop, farm) wiring system. 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insula[...]

  • Page 22

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 18 5-3. Engine Prestart Checks 804 971-A Full Gasoline 1/2 in (13 mm) Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. 1 Fuel V alve Open valve.  Fuel valve is shown in the open position. Always close fuel valve [...]

  • Page 23

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 19 5-5. Installing W elding Gun 804 755-B 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob. Insert gun end through opening until it bottoms against drive assembly . Tighten knob. 4 Gun Trigger Plug Insert into receptacle, and tighten threaded collar . 5 Mig Gun/Sp[...]

  • Page 24

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 20 5-7. W eld Process/Polarity T able W eld Process W eld Polarity Cable Connections W e ld P rocess W e ld P o l ar i ty Wire Drive Lead W ork Clamp Lead GMA W − Solid wire with shield- ing gas DCEP − Reverse polarity Connect to positive (+) out- put terminal Connect t[...]

  • Page 25

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 21 5-9. Connecting Single − Phase, 230 V olt AC Utility Input Power  This unit can provide weld out- put using the engine to power the welding power source/wire feeder OR single − phase 230 volt ac utility power can be used to power the welding pow- er source/wire fe[...]

  • Page 26

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 22 5-10. Electrical Service Guide 60 Hz Single Phase Input V oltage 230 Input Amperes At Rated Output 20 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 , Time-Delay 2 25 Normal Operating 3 30 Min Input Conductor Size In A WG 4 14 Max Recommended Input Con[...]

  • Page 27

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 23 Notes FILLET GROOVE WELD JOINT TYPES BUTT BUTT BUTT BUTT T − JOINT T − JOINT T − JOINT T − JOINT FLA T VERTICAL HORIZONT AL OVERHEAD WELD POSITION: Ref. AWS/ANSI D1.1 1G 1F 2G 2F 3G 3F 4G 4F Ref. 804 248-A[...]

  • Page 28

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 24 5-12. Threading The Welding Gun T ools Needed: 1 3 5 804 755-B / Ref. 229 573-A 2 T ighten 1 2 3 4 Pressure Indicator Scale 6 in (150 mm) 6 4 .024 Groove .030/.035 Groove Stamped .024 Stamped .030/.035[...]

  • Page 29

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 25 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight. Open pressure assembly . Pull about 6 in. (150 mm) of wire off spool. Hold tightly to keep it from unraveling. Cut off end. Pull wire th[...]

  • Page 30

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 26 SECTION 6 − OPERA TING THE WELDING GENERA TOR 6-1. Controls (See Section 6-2) 229 573 / 804 971-B 4 1 6 3 5 2 7 89 Electric Start Models Recoil Start Models 1 2 4[...]

  • Page 31

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 27 6-2. Description Of Controls (See Section 6-1 ) 1 Engine Switch Use switch to control ignition circuit. For Recoil Start: T urn switch to On position when starting engine. T urn switch to Off posi- tion to stop engine. Engine cannot be started with switch in the Off posi[...]

  • Page 32

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 28 6-3. W eld Parameter Chart Ref. 230 748C[...]

  • Page 33

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 29 6-4. Stainless Steel And 100% CO2 Weld Parameters Select Wire T ype, Polarity , and Shielding Wire Size Material Thickness Select Wire T ype, Polarity , and Shielding Gas Wi re Si ze 20 ga 18 ga 16 ga 14 ga 1/8 in. 3/16 in. 1/4 in. 5/16 in. Shop Settings (Wall or Premise[...]

  • Page 34

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 30 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord.  Generator power decreases as weld current inc reases. 1 240 V AC Receptacle RC1 RC 1 supplies 60 Hz single-phase power at weld/power speed. Ma[...]

  • Page 35

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 31 SECTION 8 − MAINTENANCE 8-1. Power Source Routine Maintenance  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.  S ee Engine Manual and Maintenance Label for important[...]

  • Page 36

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 32 8-2. Gun Routine Maintenance Stop engine and dis- connect gun before maintaining.  = Check  = Change  = Clean  = Replace Reference Every Spool Of Wire Section 8-7  Gun Casing  Nozzle,  Contact T ip Every 3 Months Section 8-7  Cracked Parts  Cra[...]

  • Page 37

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 33 8-5. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place. 2 Drive Roll The drive roll consists of two[...]

  • Page 38

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 34 8-7. Maintaining Gun Ref. 800 797-D T urn off welding power source/wire feeder . 1 Nozzle 2 Contact T ip 3 Adapter 4 Head Tube Cut off wire and disconnect gun from feeder Remove nozzle contact tip and adapter from head tube. 5 Liner Unscrew and remove liner . Lay gun cab[...]

  • Page 39

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 35 8-8. Replacing Switch And/Or Head T ube Ref. ST-800 795-C T ools Needed: 19 mm 1 3 2 4 5 6 T urn off welding power source/wire feeder and dis- connect gun. 1 Handle Locking Nut 2 Switch Housing 3 Handle 4 V ise 5 Head Tube 6 Jam Nut Remove handle locking nut. Remove swit[...]

  • Page 40

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 36 8-9. Servicing Air Cleaner aircleaner6 9/00 − 803 404 / 805 055 Stop engine. NOTICE − Do not run engine with- ou t air cleaner or with dirty element. 1 Precleaner 2 Paper Element  Do not wash paper element or clean with compressed air. Remove cover . Was h preclea[...]

  • Page 41

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 37 8-10. Adjusting Engine Speed 804 971-A T ools Needed: 3750 ± 30 rpm (62 Hz) After tuning engine, check engine speed. See table for proper no load speed. If necessary , adjust speed as follows: Start engine and run until warm. 1 Adjustment Screw T o increase speed, turn [...]

  • Page 42

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 38 SECTION 9 − TROUBLESHOOTING 9-1. T roubleshooting A. Welding T rouble Remedy No weld output or generator power out- put at ac receptacles. Be sure all equipment is disconnected from receptacles when starting unit.  AC receptacles provide auxiliary power only while e[...]

  • Page 43

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 39 T rouble Remedy Low output at generator power ac receptacles. Check engine speed, and adjust if necessary (see Section 8-10 ). Open circuit voltage is reduced as engine speed drops. Erratic output at generator power ac receptacles Check fuel level. receptacles. Have Fact[...]

  • Page 44

     Complete Parts List available at www . MillerW elds.com OM-228 042 Page 40 T rouble Remedy Engine will not start. Check fuel level (see Section 5-3). Move choke control to correct position (see Section 6-1). Open fuel valve (see Section 5- 3). Close fuel valve before moving unit or carburetor may flood and make starting dif ficult. Be sure engi[...]

  • Page 45

    OM-217 454 Page 41 SECTION 1 1 − ELECTRICAL DIAGRAMS 235 289-A Figure 1 1-1. Circuit Diagram For W elding Generator[...]

  • Page 46

    OM-228 042 Page 42 SECTION 12 − MIG WELDING (GMA W) GUIDELINES 12-1. T ypical MIG Process Connections W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pl ace wor k cl amp as close t o the weld as possible. Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Hose Shiel[...]

  • Page 47

    OM-228 042 Page 43 12-2. T ypical MIG Process Control Settings  These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications.  These settings are guidelines only . Material and wire type, joint design, fitup, position, shie[...]

  • Page 48

    OM-228 042 Page 44 12-3. Holding And Positioning W elding Gun  W elding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger , be sure wire is no more than 1/2 in (13 mm) past e nd of noz zle, and tip o f wir e is posi tion ed corre ctly on se am. S-0421-A  W elding wire is energized when gun trigger is p[...]

  • Page 49

    OM-228 042 Page 45 12-4. Conditions That Affect Weld Bead Shape  Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. S-0634-A  W eld bead shape depends on gun angle, direction of travel, electrode extension (stickout), tr[...]

  • Page 50

    OM-228 042 Page 46 12-5. Gun Movement During Welding  Normally , a single stringer bead is satisfactory for most narrow groove weld joints; however , for wide groove weld joints or bridging acros s gaps, a weave bead or multiple stringer beads works better . 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement A[...]

  • Page 51

    OM-228 042 Page 47 12-8. T roubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long. U[...]

  • Page 52

    OM-228 042 Page 48 12-10. T roubleshooting − Excessive Penetration Good Penetration Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Excessive Penetration S-0639 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase travel speed. W rong [...]

  • Page 53

    OM-228 042 Page 49 12-13. T roubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. S-0640 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase and/or maintain steady travel speed. W rong polarity [...]

  • Page 54

    OM-228 042 Page 50 12-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. Application Gas Spray Arc Steel Short Circuiting Steel Short Ci[...]

  • Page 55

    OM-228 042 Page 51 SECTION 13 − GENERA T OR POWER GUIDELINES  The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 13-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3[...]

  • Page 56

    OM-228 042 Page 52 13-3. 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  Us e 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

    OM-228 042 Page 53 13-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting 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 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 2[...]

  • Page 58

    OM-228 042 Page 54 13-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts 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 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 i[...]

  • Page 59

    OM-228 042 Page 55 13-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 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[...]

  • Page 60

    OM-228 042 Page 56 13-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install and ground this eq[...]

  • Page 61

    OM-228 042 Page 57 13-1 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. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 84[...]

  • Page 62

    OM-228 042 Page 58 Notes SOCKET/WRENCH SELECTION T ABLE (U.S. ST ANDARD) SOCKET/WRENCH SELECTION T ABLE (METRIC) Specifications Socket or Wrench Size Specifications Socket or W rench Size Bolt Diameter Decimal Equivalent Bolt Nut Bolt Diameter U.S. Decimal Equivalent Bolt Nut 1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm 5/16 in .3125 in [...]

  • Page 63

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 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 . The expe[...]

  • Page 64

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX : 920-735-4134 Int ernati onal F A X: 920-735-4125 European Headqua rters − [...]