201104

176 712K

Generator Power Application Guide

Largest fuel capacity means longest generator run time! See page 2.

Blue Star 145/185

4,500 or 6,000 watt models available 145 or 185 Amps of welding power

Bobcat 225

11,000 watts of generator power 225 Amps of welding power

Bobcat 250

11,000* watts of generator power

Trailblazer 302 and 275 DC

11,000* watts of generator power
(12,000 watts with EFI engine)

(12,000 watts with EFI engine) 250 Amps of welding power Diesel and LP models also available Why buy just a generator when you can buy a generator that also welds? Your best value for power is a Miller welder/AC generator because it is

325 Amps of welding power Diesel and LP models also available

J Competitively

generators.

priced compared to regular

J Versatile120

& 240 volts AC power and welding capabilities from the same machine.
PRINTED IN USA

Welder/AC Generator: Best Value For Power Needs

While you might not need a generator or welder for daily use, investing in a machine that performs both duties makes economic sense. Like a regular generator, a Miller welder/AC generator provides 120 and 240 volts AC generator power. The 4,500 to 11,000 watt output capability of Millers mid-size generators is also suitable for home use. What are the biggest benefits to a Miller welder/AC generator? J At about the same cost as a regular generator, Miller generators are also excellent welding power sources capable of welding material up to 1/2 in. thick or more. J Millers 3-year, True Blue Total Parts warranty is longer than typical 1-year, generator warranties. J Low Fuel Consumption The Bobcat will run about 14 hours under a continuous load of 4000 watts of generator power. Weld at 150 Amps at 40% duty cycle for 16 hours! J Accu-Rated Miller generators means they deliver the power that is promised. Patented self-cooling stator allows Miller generators to perform at 100% duty cycle, even in 104F heat! And the Bobcats skewed rotor helps provide smoother power than other brands.

Table Of Contents

1. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. How Much Generator Power Do You Need? . . . . . . . . . . . . . . . . . . 3. Wattage Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. Selecting Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . 7. Grounding When Supplying Building Systems . . . . . . . . . . . . . . . . 8. Power Required To Start A Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. How Much Power Can The Generator Supply? . . . . . . . . . . . . . . . 10. Typical Connections To Supply Standby Power . . . . . . . . . . . . . . . 11. Wiring Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . .

1 2 3 4 5 6 6 7 7 8 9

12. Selecting Extension Cord (Use Shortest Cord Possible) . . . . . . . . 10

J J

See Owners Manual for meaning of safety symbols and complete safety instructions. For more detailed information, read Owners Manual, or call the Factory Applications Engineering Department at (920) 735-4265.

WARNING

GENERATOR POWER can be hazardous.

Read and follow all labels and the Owners Manual carefully. Only qualified persons are to install, operate, or service this unit according to all applicable codes and safety practices. Keep children away. Wearers of pacemakers and other Implanted Medical Devices should keep away.

Notes

1. Safety

WARNING
ELECTRIC SHOCK can kill.

Do not touch live electrical parts. Use only grounded or double insulated equipment. Stop engine before making internal inspection or reconnection. Properly install and ground generator according to its Owners Manual and all applicable national, state, and local codes. Connect equipment grounding terminal to a proper earth ground. Do not connect to any electrical distribution system normally supplied by utility power unless a proper transfer switch and grounding procedure are employed. Have only qualified persons make electrical connections. Use all code-required methods for shock and overcurrent protection.

Using a generator indoors CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER use inside a home or garage, EVEN IF doors and windows are open. Only use OUTSIDE and far away from windows, doors, and vents.

MOVING PARTS can cause serious injury.

Keep away from moving parts such as fans, belts, and rotors. Keep all doors, panels, covers, and guards closed and securely in place.

ELECTRIC SPARKS can cause fire.

If using generator power only and not welding, disconnect both welding cables to prevent live electrode from causing electric shock and fire hazards. Watch for fire. Keep a fire extinguisher nearby, and know how to use it.

The weld output terminals are electrically energized when the engine is running and the contactor, if applicable, is energized.

LOW VOLTAGE AND FREQUENCY can damage electrical equipment.

Turn off or unplug all electrical equipment connected to generator power receptacles before starting or stopping the engine.

When starting or stopping, the engine has low speed which causes low voltage and frequency.

Page 1

2. How Much Generator Power Do You Need? EXAMPLE WORKSHEET

Column A
TOOL OR APPLIANCE STARTING WATTS

Column B
RUNNING WATTS

Column C
ADDITIONAL STARTING WATTS

1. Refrigerator 2. Sump Pump 3. Table Saw 4. 5. 6. 7.

2,200 1,300 6,300

700 800 1,800

1,500 500 4,500

Use this easy reference to determine the generator size you need. To select a generator with enough power output in watts, add the watts for the items you want to simultaneously run. Tools and appliances with induction motors may require 3 7 times the listed wattage when starting. All data listed is approximatecheck your tool/appliance for specific wattage requirements. Your actual requirements will vary (see Sections 4 and 7). This worksheet will focus on determining your starting and running watt needs. Amount of generator power you need depends on your power requirements. Generally, a higher-wattage generator lets you power more items at once. 1 Select the items you wish to power at the same time. Using the chart in Section 3, fill in the starting watts (Column A) and running watts (Column B) requirements. 2 Add all the items in the RUNNING WATTS column (Column B) to determine total running watts. Enter the total in the TOTAL RUNNING WATTS boxes. 3 Subtract RUNNING WATTS (Column B) from STARTING WATTS (Column A). Enter the results in the ADDITIONAL STARTING WATTS column (Column C). Select the ONE INDIVIDUAL ITEM with the highest number of ADDITIONAL STARTING WATTS. Take this ONE NUMBER, add it to your TOTAL RUNNING WATTS, and enter the total in the TOTAL WATTS NEEDED box.

TOTAL RUNNING WATTS =

3,300

4,500
HIGHEST ADDITIONAL STARTING WATTS

With this example you need a generator that produces at least 3,300 total running watts and 7,800 total watts.

3,300

TOTAL RUNNING WATTS

7,800

TOTAL WATTS NEEDED

EXAMPLE WORKSHEET
Column A
TOOL OR APPLIANCE STARTING WATTS

Column B
RUNNING WATTS

Column C
ADDITIONAL STARTING WATTS

1. 2. 3. 4. 5. 6. 7.
TOTAL RUNNING WATTS =

HIGHEST ADDITIONAL STARTING WATTS (COLUMN C)

I need a generator that produces at least ________ total running watts and ________ total watts.

+
TOTAL RUNNING WATTS

=
TOTAL WATTS NEEDED

Page 2

3. Wattage Reference Guide

HOUSEHOLD
Appliances
Dishwasher (cool dry) Electric Range (6-inch element) Microwave Oven (625 watts) Refrigerator or Freezer Automatic Washer Clothes Dryer (gas / electric) Garage Door Opener (1/4 hp) Furnace Fan, Gas or Fuel Oil (1/4 hp) Well Pump (1/3 hp) Sump Pump (1/3 hp) Central Air Conditioner (20,000 BTU) Starting Watts 1,400 0 800 2,200 2,300 1,800 / 1,800 1,100 1,000 1,400 1,300 3,300 Running Watts 700 1,500 625 700 1,150 700 / 5,750 550 600 750 800 2,500

CONTRACTOR TOOLS
Tool
Hand Drill (1/2 in) Circular Saw (8-1/4 in) Table Saw (10 in) Band Saw (14 in) Air Compressor (1-1/2 hp) Electric Chain Saw (2 hp, 14 in) Spectrum 625 Plasma Cutter (30 amp, 230 volts, 1/2 in cut) Millermatic 212 MIG Welder (30210 amps, 230 volt) Flood Lights (vapor) Submersible Pump (400 gph) Centrifugal Pump (900 gph) High Pressure Washer (1 hp) Wet & Dry VAC (1.7 hp) Starting Watts 600 1,400 6,300 2,500 8,200 1,100 3,500 6,500 1,250 600 900 6,100 900 Running Watts 600 1,400 1,800 1,100 2,200 1,100 3,500 6,500 1,000 200 500 1,600 900

FARM EQUIPMENT
Machine
Barn Cleaner (5 HP) Silo Unloader Portable Conveyer (1/2 hp) Milker, Vacuum Pump (2 hp) Farm Duty MotorsConveyers, Feed Augers, Air Compressors, Etc. (1-1/2 hp) Washer, 2 gal/min (550 PSI) Starting Watts 11,600 12,200 3,400 10,500 8,200 4,500 Running Watts 3,000 4,300 1,000 2,800 2,200 1,400

INDUSTRIAL MOTORS
Motor
Split Phase (1/2 hp) Capacitor Start, Induction Run (1-1/2 hp) Capacitor Start, Capacitor Run (1-1/2 hp) Fan (1/2 hp) Starting Watts 3,175 8,200 8,100 3,500 Running Watts 875 2,200 2,000 1,100

Page 3

4. Frequently Asked Questions

How many watts does it take to power basic items in an average size house? In a typical home, essential items use about 4000 6000 watts of power. Select a generator that can provide the necessary power while maintaining rated voltage. Low voltage may damage appliances and other equipment (see power curve example below).
300 150 264 132 250 125

GENERATOR POWER CURVE BOBCAT

11,000 watts

10%

AC POWER VOLTS

216 108 200 100 150 100 50 0 75 50 25 0

0 0

20 10

40 20

60 80 100 120 140 160 AC POWER AMPS AT 120 VOLTS 30 40 50 60 70 80 AC POWER AMPS AT 240 VOLTS

180 90

200 100

220 110

Tools and motors are designed to operate within 10% of 120/240 VAC. The Bobcats power generator provides strong power while keeping the voltage within 10%of 120/240 VAC. This increases tool/motor performance and life.

What is the difference between running watts and starting watts? Running watts are the continuous watts needed to keep items running. Starting watts are extra watts needed for two to three seconds to start motor-driven products like a refrigerator or circular saw. Why is only one additional starting watt item used to calculate your total watt requirement? Unlike running watts, starting watts are only needed during the first few seconds of operation. In most cases, only one item will start or cycle at the same time, therefore this is the most accurate estimate. What if I cant determine the running or the starting watt requirement for a tool or appliance? If the running watts are not on the tool or appliance, you may estimate using the following equation: WATTS = VOLTS x AMPS. Only motor-driven items will have an additional starting requirement. The additional starting watts required in most cases may be estimated at 3 7 times the rated running watts. VOLTS 115 AMPS 4.5 Hz 60 Rating Data

Resistive Load (requires constant amount of power)

Non-Resistive Load (Motors require as much as 3 7 times more power when starting than when running)

S-0623

Page 4

5. Selecting Generator Equipment

1 Generator Power Receptacles Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated Equipment

. Be
1

sure equipment has double insulated symbol and/or wording on it. Do not use 2-prong plug unless equipment is double insulated.

3 OR
Ref. ST-159 730 / ST-800 577

6. Grounding Generator To Truck Or Trailer Frame !

Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators.

!
2
GND/PE

1 Metal Vehicle Frame 2 Equipment Grounding Terminal 3 Grounding Cable Use #8 AWG or larger insulated copper wire.

!
Electrically bond generator frame to vehicle frame by metal-to-metal contact. 1

Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord.
S-0854

Page 5

7. Grounding When Supplying Building Systems

1 Equipment Grounding Terminal 2 Grounding Cable Use #8 AWG or larger insulated copper wire. 3 Ground Device

. Use
1
GND/PE

ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators.

ST-800 576-B

Page 6

8. Power Required To Start A Motor

1 Motor Start Code 4 1 3 VOLTS 230 CODE M HP 1/4 AC MOTOR AMPS 2.5 Hz 60 PHASE 1 2 2 Running Amperage 3 Motor HP 4 Motor Voltage 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. Step 2: Find Motor HP and Volts. Step 3: Determine starting amperage (see example). Welding generator amperage output must be at least twice the motors running amperage. Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP G 6.3 H 7.1 J 8.0 K 9.0 L 10.0 M 11.2 N 12.5 P 14.0

kVA/HP x HP x 1000 VOLTS

= STARTING AMPERAGE

EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2

11.2 x 1/4 x 1000 = 12.2 A Starting the motor requires 12.2 amperes. 230

S-0624

9. How Much Power Can The Generator Supply?

2 1 Limit Load To 90% Of Generator Output Always start non-resistive (motor) loads in order from largest to smallest, and add resistive loads last. 1 2 5 Second Rule If motor does not start within 5 seconds, turn off power to prevent motor damage. Motor requires more power than generator can supply.
803 636 / S-0625

Page 7

10. Typical Connections To Supply Standby Power

Properly install, ground, and operate this equipment according to its Owners Manual and national, state, and local codes.

1 Utility Electrical Service

2 Transfer Switch

3 Fused Disconnect Switch (If Required)

4 Welding Generator Output

5 Essential Loads

Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install, ground, and operate this equipment according to its Owners Manual and national, state, and local codes. ment is required if generator will supply standby power during emergencies or power outages.

Switch transfers the electrical load from electric utility service to the generator. Transfer load back to electric utility when service is restored. Install correct switch (customer-supplied). Switch rating must be same as or greater than the branch overcurrent protection. 3 Fused Disconnect Switch Install correct switch (customer-supplied) if required by electrical code. 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular (utility) system voltage and wiring.

Connect generator with temporary or permanent wiring suitable for the installation. Turn off or unplug all equipment connected to generator before starting or stopping engine. When starting or stopping, the engine has low speed which causes low voltage and frequency. 5 Essential Loads Generator output may not meet the electrical requirements of the premises. If generator does not produce enough output to meet all requirements, connect only essential loads (pumps, freezers, heaters,etc. See Section 2).

. Customer-supplied equip-

1 Utility Electrical Service 2 Transfer Switch (Double-Throw) Page 8

11. Wiring Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)

Tools Needed: 4

1 3

120V 120V 240V

5 6 2 3 4

240V 6 5

Plug is MILLER Part No. 119 172

Plug1 7/99 120 813-D

The plug can be wired for a 240 V, 2-wire load or a 120/240V 3-wire load. See , circuit diagram in Owners Manual. 1 Plug Wired for 120/240 V, 3-Wire Load

2 3 4 5 6

Plug Wired for 240 V, 2-Wire Load Neutral (Silver) Terminal Load 1 (Brass) Terminal Load 2 (Brass) Terminal Ground (Green) Terminal

Strip cord jacket back enough to separate conductors. Strip conductors enough to make good contact with plug terminals. Make plug connections and reinstall outer shell and cord grip. Tighten assembly screws onto shell. Do not overtighten. Page 9

When wired for 120 V loads, each duplex receptacle shares a load with one half of 240 V receptacle.

12. Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths For 120 Volt Loads

Use GFCI protection if operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Maximum Allowable Cord Length In Feet (Meters) For Conductor Size (AWG)* Current In Amperes
5 7 10 15 20 25 30 35 40 45 50

Load In Watts
600 840 1200 1800 2400 3000 3600 4200 4800 5400 6000

8
350 (106)

10
225 (68) 150 (46) 112 (34) 75 (23) 50 (15) 37 (11) 37 (11)

12
137 (42) 100 (30) 62 (19) 37 (11) 30 (9)

14
100 (30) 62 (19) 50 (15) 30 (9)

400 (122) 400 (122) 300 (91) 225 (68) 175 (53) 150 (46) 125 (38) 112 (34) 100 (30) 87 (26) 275 (84) 175 (53) 137 (42) 112 (34) 87 (26) 75 (23) 62 (19) 62 (19) 50 (15)

250 (76) 175 (53) 112 (34) 87 (26) 62 (19) 50 (15) 50 (15) 37 (11)

*Conductor size is based on maximum 2% voltage drop

Page 10

Cord Lengths For 120 Volt Loads

Use GFCI protection if operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Maximum Allowable Cord Length In Feet (Meters) For Conductor Size (AWG)* Current In Amperes
5 7 10 15 20 25 30 35 40 45 50

Load In Watts
1200 1680 2400 3600 4800 6000 7000 8400 9600 10,800 12,000

8
700 (213)

10
450 (137) 300 (91) 225 (69) 150 (46) 100 (31) 75 (23) 75 (23)

12
225 (84) 200 (61) 125 (38) 75 (23) 60 (18)

14
200 (61) 125 (38) 100 (31) 60 (18)

800 (244) 800 (244) 600 (183) 450 (137) 350 (107) 300 (91) 250 (76) 225 (69) 200 (61) 175 (53) 550 (168) 350 (107) 275 (84) 225 (69) 175 (53) 150 (46) 125 (38) 125 (38) 100 (31)

500 (152) 350 (107) 225 (69) 175 (53) 125 (38) 100 (31) 100 (31) 75 (23)

*Conductor size is based on maximum 2% voltage drop

Page 11

Miller Electric Mfg. Co.

An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters-USA USA Phone: 9207354505 AutoAttended USA & Canada FAX: 9207354134 International FAX: 9207354125 Web Site-www.MillerWelds.com