Miller Electric 400P, 500 X Generator Power Guidelines, Selecting Equipment, Al-to-metal contact

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SECTION 12 − GENERATOR POWER GUIDELINES

.The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.

12-1. Selecting Equipment

1

2

3

OR

1Generator Power Receptacles − Neutral Bonded To Frame

23-Prong Plug From Case Grounded Equipment

32-Prong Plug From Double Insulated Equipment

.Be sure equipment has double

insulated symbol and/or word- ing on it.

! Do not use 2-prong plug un- less equipment is double in- sulated.

gen_pwr 2007−04 − Ref. ST-159 730 / ST-800 577

12-2. Grounding Generator To Truck Or Trailer Frame

! Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards.

! Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators.

			1	Equipment Grounding
				Terminal (On Front Panel)
			2	Grounding Cable (Not
	1			Supplied)
	1		3	Metal Vehicle Frame
			3	Metal Vehicle Frame
GND/PE	2		Connect cable		from	equipment
			ground terminal to metal vehicle
			frame. Use #10 AWG or larger
			insulated copper wire.
		3	. Electrically		bond	generator
		3		frame to vehicle frame by met-
				frame to vehicle frame by met-

al-to-metal contact.

! Bed liners, shipping skids, and some running gear insu- late the welding generator from the vehicle frame. Al- ways connect a ground wire from the generator equip- ment grounding terminal to bare metal on the vehicle frame as shown.

! If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord.

S-0854

OM-4421 Page 61

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Contents File Engine Drive OM-4421215 075QProcesses DescriptionFrom Miller to You Table of Contents − Maintenance & Troubleshooting Standards DirectivesDecrot1/07 Decrotsound6/05 Manufacturer European Contact Notified BodyHOT 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 Manufacturer’s Rating Labels Some symbols are found only on export products Symbols And DefinitionsWeld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models Volt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG ModeDuty Cycle And Overheating Fuel Consumption100% Duty Cycle At 400 Amperes 15 kVA/kW Three-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 12 kVA/kW Single-Phase AC Output No Weld LoadGrounding1 − InstallationInstalling Welding Generator Location/Airflow ClearanceUsing Lifting Eye Mounting Welding Generator Stop engine and let cool Installing Exhaust PipeConnecting The Battery Activating The Dry Charge Battery If ApplicableEngine Prestart Checks Coolant Recovery TankStop engine Connecting To Weld Output TerminalsStick and TIG Welding MIG and Fcaw Welding350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Connecting to WeldSelecting Weld Cable Sizes 150 ft 200 ft 250 ftSocket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsOM-4421 Front 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 OM-4421 Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV ModelsElectric shock can kill Voltage/Amperage Adjust Switch And Remote 14 Receptacle14 AC/DC Voltmeter Optional Process/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 enRear Of Panel Three-Phase Power ConnectionClose panel opening if no connections are made to generator 240 V 15 a AC South African Receptacle RC1 Optional Generator Power ReceptaclesSupplementary Protector CB2 Supplementary Protector CB3 Maintenance Label − Maintenance & TroubleshootingRoutine Maintenance Checking Generator Brushes To clean air filter Servicing Air CleanerInspecting And Cleaning Optional Spark Arrestor Muffler Standard Model Idle Speed Ad- justment Adjusting Engine SpeedWeld/Power Speed Adjustment Engine Speed No LoadWhile draining fuel tank Servicing Fuel And Lubrication SystemsTo change oil and filter To replace primary fuel filterOverload Protection Welding − CC Models TroubleshootingWelding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Only Standard Generator PowerEngine Welding Symbols Circuit Diagram For CC Welding Generator − Electrical Diagrams223 522-B Circuit Diagram For CC/CV Welding Generator 223 523-B 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 − 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 -1Item Control Box Assembly − CC/CV ModelsTD1 214 3634 Panel, Front w/Components − CC ModelsPanel, Front w/Components − CC Models -1Item 40 39 Panel, Front w/Components − CC/CV ModelsPanel, Front w/Components − CC/CV Models -1Item 170 34 36 27 26 Hardware is common Not available unless listed602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Wiring Harnesses PLG4 Harness, receptacle auxiliary power export models includesPage 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