Miller Electric 500D, 600 X manual Run-In Procedure Using Load Bank, Keep exhaust and pipe away

Page 79

13-2. Run-In Procedure Using Load Bank

 

Stop engine.

 

Do not touch hot exhaust pipe,

 

engine parts, or load bank/grid.

4

Keep exhaust and pipe away

from flammables.

2

NOTICE − Do not perform run-

in procedure at less than 20

1

volts weld output and do not

exceed duty cycle or equip-

 

ment damage may occur.

 

1

Load Bank

 

Turn all load bank switches Off. If

 

needed, connect load bank to 115

 

volts ac wall receptacle or genera-

 

tor auxiliary power receptacle.

 

2

Welding Generator

 

Place A/V range switch in maxi-

 

mum position, A/V control in mini-

 

mum position, and Output Selector

 

switch (if present) in either DC

 

position.

 

3

Weld Cables

 

Connect load bank to generator

 

weld output terminals using proper

 

size weld cables with correct

 

connectors. Observe correct

 

polarity.

 

Start engine and run for several

3

minutes.

Set load bank switches and then

 

 

adjust generator A/V control so

 

load equals rated voltage and

 

current of generator (see name-

 

plate, rating label, or the specifi-

 

cations section in this manual).

 

Check generator and load bank

 

meters after first five minutes then

 

every fifteen minutes to be sure

 

generator is loaded properly.

 

NOTICE − Check oil level frequent-

 

ly during run-in; add oil if needed.

 

It is recommended to run the weld-

 

ing generator for two hours mini-

 

mum and up to four hours under

 

load. Place A/V control in minimum

 

position, then turn off load bank to

 

remove load. Run engine several

 

minutes at no load.

 

 

Stop engine and let cool.

 

4

Engine Exhaust Pipe

 

Repeat procedure if wetstacking

 

is present.

S-0683

OM-4428 Page 75

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Contents File Engine Drive OM-4428215 932KProcesses DescriptionFrom Miller to You Table of Contents Troubleshooting HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationIndique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LE Soudage peut provoquer un in cendie ou une explosionDES Organes Mobiles peuvent pro voquer des blessures ’EXPLOSION DE LA Batterie peu’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresEn ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMF− 50 h Std − DefinitionsStd CC Models Manufacturer’s Rating LabelsSome symbols are found only on CE products Symbols And DefinitionsLifting Eye Weight Rating − SpecificationsWeld, Power, And Engine Specifications Dimensions, Weights, And Operating AnglesVolts Volt-Ampere Curves For CC ModelsVolt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG ModeFuel Consumption Curve shows typical fuel use under weld or power loadsDuty Cycle And Overheating AC Generator Power Curve100% Duty Cycle At 500 Amperes 12 kVA/kW Single-Phase AC Output No Weld Load Optional Three-Phase Generator Curves20 kVA/kW Three-Phase AC Output No Weld Load Grounding1 − InstallationInstalling Welding Generator Location/Airflow ClearanceUsing Lifting Eye Mounting Welding Generator After installing cylinder, wait at Installing Exhaust PipeStop engine and let cool Connecting The Battery Activating The Dry Charge Battery If ApplicableFuel Engine Prestart ChecksDeutz F4L2011 Engine Deutz F3L912 EngineMIG and Fcaw Welding Connecting To Weld Output TerminalsCorrect Installation Stick and TIG WeldingOutput terminals Connecting to WeldSelecting Weld Cable Sizes 45 m 60 m 70 m 90 m 105 m 120 mSocket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsFront Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsWeld Controls Engine Starting ControlsTo Start Engine Gauges And MetersWeld Control/Arc Condition Information Label Remote Amperage Control On CC Models OptionalExample Combination Remote Amperage Control Stick Work like a Pro Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV Models14 AC/DC Voltmeter Optional Voltage/Amperage Adjust Switch And Remote 14 ReceptacleProcess/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsExample Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models OptionalIf a Supplementary − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles At least once a month, run enAre made Generator Rear Of PanelClose Connections240 V 15 a AC South African Receptacle RC1 Optional Generator Power Receptacles Standard ModelsSupplementary Protector CB2 Supplementary Protector CB3 Generator power is not affected by weld output Generator Power Receptacles Export ModelsMaintenance Label Deutz F4L2011-Powered Units − Maintenance Deutz F4L2011−POWERED UnitsRoutine Maintenance Deutz F4L2011-Powered Units Checking Generator Brushes To clean air filter Servicing Air Cleaner Deutz F4L2011-Powered UnitsReinstall cleanout plug Tools Needed 3/8 Spark Arrestor Muffler Cleanout PlugCovering cleanout hole Blow out cleanout hole. If nothingModels With Automatic Idle Optional Adjusting Engine Speed Deutz F4L2011-Powered UnitsStandard Models Do not set engine speed higher than specifiedTo replace secondary fuel filter To change oil and filterTo drain water from fuel system To replace primary fuel filterWhen a supplementary protector Overload Protection Deutz F4L2011-Powered UnitsMaintenance Label Deutz F3L912-Powered Units − Maintenance Deutz F3L912−POWERED UnitsRoutine Maintenance Deutz F3L912-Powered Units Checking Generator Brushes Cleanings Ment is not covered by the warrantyClean or replace primary element if dirty See note above before cleaning. ReSpark Arrestor Muffler Cleanout Plug Adjusting Engine Speed Deutz F3L912-Powered Units To change oil and filter Overload Protection Deutz F3L912-Powered Units Troubleshooting − TroubleshootingWelding − CC Models Welding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Only Standard Generator PowerEngine − Electrical Diagrams 215 221-E OM-4428 235 275-A OM-4428 215 806-E OM-4428 235 276-A OM-4428 215 807-D OM-4428 215 808-D Wetstacking − RUN-IN ProcedureWelding Generator Keep exhaust and pipe away Run-In Procedure Using Load BankFrom flammables Manual Run-In Procedure Using Resistance GridSpecifications section in this Just generator A/V control soElectrically Bond Generator − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer FrameAmperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codesFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible CC CC Models Only CV CC/CV Models Only − Parts ListDeutz F4L2011 en Dia Part Description Quantity Dia Part Description Quantity Mkgs CC191 Control Box Assembly − CC Models PLG3 Control Box Assembly − CC/CV Models 193 SWITCH, rotary 6 position gold contacts Panel, Front w/Components − CC Models GFCI1 Temp Panel, Front w/Components − CC/CV Models -1Item Panel, Front w/Components − CC/CV ModelsPC6 192 PC4, PC5 189 2827 Hardware is common602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly -1Item Main Rectifier AssemblyPage Your distributor also gives ServiceSupport Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact

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