Miller Electric 400P, 500 X manual Overload Protection

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9-8. Overload Protection

! Stop engine.

2

9

8

7

4 5

1

.When a supplementary protector,

circuit breaker or fuse opens, it usu- ally indicates a more serious problem exists. Contact Factory Authorized Service Agent.

1Fuse F1

2Fuse F2

F1 and F2 protect the stator exciter wind- ing from overload. If F1 opens, weld and generator power is low or stops entirely. If F2 opens, weld output is low or stops entirely. 4 kVA/kW generator power is still available.

3Circuit Breaker CB4 (Not Shown)

4Supplementary Protector CB5 (CC/CV Models Only)

5Supplementary Protector CB6 (CC/CV Models Only)

6Circuit Breaker CB10 (Not Shown)

7Supplementary Protector CB11

8Supplementary Protector CB12

9Supplementary Protector CB13

10Circuit Breaker CB14 (Not Shown)

CB4 protects the welding arc drive (dig) circuit. If CB4 opens, electrode may stick to the workpiece more frequently during low voltage (short arc length) conditions. CB4 automatically resets when the fault is corrected.

CB5 protects the 24 volt ac output to re- mote receptacle RC14, and 24 volt output to field current regulator board PC1 (CC/ CV models only). If CB5 opens, weld out- put and 24 volt output to RC14 stops. On units with optional three-phase genera- tor, generator power output at receptacle RC5 also stops if CB5 opens.

CB6 protects the 115 volt ac output to re- mote receptacle RC14 (CC/CV models only). If CB6 opens, 115 volt output to RC14 stops.

CB10 protects the engine battery circuit. If CB10 opens, the engine will not crank. CB10 automatically resets when the fault is corrected.

CB11 protects the weld control circuit. On

CCmodels, if CB11 opens the max OCV circuit does not work and open circuit voltage is variable at all times (see max OCV note under Weld Controls in Section 6-2). If CB11 opens on CV models, weld output stops (generator power is still available).

CB12 protects the field flashing circuit. If CB12 opens, the generator may not ex- cite at start-up and weld and generator power output may not be available.

CB13 protects the engine control circuit. If CB13 opens, the engine does not crank.

CB14 protects throttle solenoid TS1 on units with auto idle option. If CB14 opens, the engine does not run at idle speed. CB14 automatically resets when the fault is corrected.

Press button to reset supplementary pro- tector.

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Contents Description OM-4421215 075QProcesses File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting Directives StandardsDecrot1/07 Manufacturer European Contact Notified Body Decrotsound6/05Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosionEngine Hazards Compressed Air HazardsFire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation Indique des instructions spécifiquesLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu DES Organes Mobiles peuvent pro voquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures ’EMPLOI Excessif peutInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité En ce qui concerne les implants médicaux− Definitions − 50 h StdStd Manufacturer’s Rating Labels Symbols And Definitions Some symbols are found only on export products− Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models TIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Duty Cycle And Overheating100% Duty Cycle At 400 Amperes 12 kVA/kW Single-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 15 kVA/kW Three-Phase AC Output No Weld LoadLocation/Airflow Clearance − InstallationInstalling Welding Generator Grounding1Using Lifting Eye Mounting Welding Generator Installing Exhaust Pipe Stop engine and let coolActivating The Dry Charge Battery If Applicable Connecting The BatteryCoolant Recovery Tank Engine Prestart ChecksMIG and Fcaw Welding Connecting To Weld Output TerminalsStick and TIG Welding Stop engine150 ft 200 ft 250 ft Connecting to WeldSelecting Weld Cable Sizes 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mConnecting To Remote 14 Receptacle RC14 On CC/CV Models SocketOM-4421 − Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionEngine Gauges And Meters Engine Starting ControlsTo Start Weld ControlsRemote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Combination Remote Amperage Control Stick OM-4421 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionVoltage/Amperage Adjust Switch And Remote 14 Receptacle Electric shock can kill14 AC/DC Voltmeter Optional Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIGAt least once a month, run en − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles If a SupplementaryThree-Phase Power Connection Rear Of PanelClose panel opening if no connections are made to generator Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Supplementary Protector CB2 Supplementary Protector CB3 − Maintenance & Troubleshooting Maintenance LabelRoutine Maintenance Checking Generator Brushes Servicing Air Cleaner To clean air filterInspecting And Cleaning Optional Spark Arrestor Muffler Engine Speed No Load Adjusting Engine SpeedWeld/Power Speed Adjustment Standard Model Idle Speed Ad- justmentTo replace primary fuel filter Servicing Fuel And Lubrication SystemsTo change oil and filter While draining fuel tankOverload Protection Troubleshooting Welding − CC ModelsWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine Welding Symbols − Electrical Diagrams Circuit Diagram For CC Welding Generator223 522-B Circuit Diagram For CC/CV Welding Generator 223 523-B − RUN-IN Procedure WetstackingWelding Generator Run-In Procedure Using Load Bank Keep exhaust and pipe awayFrom flammables Just generator A/V control so Run-In Procedure Using Resistance GridSpecifications section in this ManualGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Electrically Bond GeneratorUse ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Parts List 128 93 −6 105 104 100 101 102 103 Main Assembly 010 Figures 13-2 Figures 13-4 Control Box Assembly − CC Models 087 Control Box Assembly − CC/CV Models Control Box Assembly − CC/CV Models -1ItemTD1 214 Panel, Front w/Components − CC Models 3634Panel, Front w/Components − CC Models -1Item Panel, Front w/Components − CC/CV Models 40 39Panel, Front w/Components − CC/CV Models -1Item 170 Hardware is common Not available unless listed 34 36 27 26602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Wiring Harnesses Harness, receptacle auxiliary power export models includes PLG4Page Service Your distributor also givesSupport For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s
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