Miller Electric 400P, 500 X manual Control Box Assembly − CC/CV Models

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							803 648-F
					Figure 13-3. Control Box Assembly − CC/CV Models
Item			Dia.		Part	Description	Quantity
	No.		Mkgs.		No.	Description	Quantity
					Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1Item 114)

. . .	1	. . . F1, F2		. . *085 874 . .		FUSE, mintr cer slo-blo 10A 250V	. . . 2
. . .	2	. . . . . . . . . .		. . .	046 432 . .	HOLDER, fuse mintr .250 x 1.250	. . . 2
. . . 3		. . . . . . . . . .		. . .	201 077 . .	CONTROL BOX, lh	. . . 1
. . . 4		. . . . . . . . . .		. . .	201 078 . .	CONTROL BOX, rh	. . . 1
. . .	5	. . . . CR3		. . ♦090 104 . .		RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg	. . . 1
. . .	6	. . . . CR8		. . .	197 325 . .	RELAY, encl 12vdc spst 70a 4pin flange mtg	. . . 1
. . .	7	. . . . CR1		. . .	090 104 . .	RELAY, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg	. . . 1
. . .	8	. . . . CR6		. . ♦090 104 . .		RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg	. . . 1
. . . 9			D10/C10, D11/C11 189 701 . .			DIODE/CAPACITOR BOARD	. . . 2
. . . 10		.	. . . CB14	. . ♦230 635 . .		CIRCUIT BREAKER, auto reset 12vdc 8 amp	. . . 1
. . . 11		.	. . . CB10	. . .	190 374 . .	CIRCUIT BREAKER, auto reset 12VDC 40A	. . . 1
. . . 12		.	. . . CR5	. . .	223 710 . .	RELAY, encl 12VDC dpst−no 25A 6pin flange	. . . 1
. . . 13		. . . . . . . . . .		. . .	201 079 . .	COVER, control box	. . . 1
. . . 14		.	. . . PC7	. . ♦195 706 . .		MODULE, pull to idle, two output, 7 pin	. . . 1
. . . 15		.	. . . SR1	. . .	035 704 . .	RECTIFIER, integ 40A 800V	. . . 1
. . . 16		.	. . . CR4	. . ♦113 247 . .		RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg	. . . 1
. . . 17		.	. . . PC9	. . .	192 224 . .	CIRCUIT CARD ASSY, display	. . . 1
. . . 18		. . . . . . . . . .		. . .	134 201 . .	STAND-OFF, support pc card	. . . 3
. . . 19		.	. . . . C9 .	. . . .	087 110 . .	CAPACITOR, elctlt 240uf 200VDC	. . . 1

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Contents Description OM-4421215 075QProcesses File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting Standards DirectivesDecrot1/07 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 blessures’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque 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− 50 h Std − DefinitionsStd Manufacturer’s Rating Labels Symbols And Definitions Some symbols are found only on export productsWeld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models TIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV ModelsDuty Cycle And Overheating Fuel Consumption100% 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 ControlsWeld Control/Arc Condition Information Label Remote Amperage Control On CC Models OptionalExample Combination Remote Amperage Control Stick OM-4421 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionElectric shock can kill Voltage/Amperage Adjust Switch And Remote 14 Receptacle14 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 SupplementaryRear 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 & 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 Wetstacking − RUN-IN ProcedureWelding Generator Keep exhaust and pipe away Run-In Procedure Using Load BankFrom 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 Your distributor also gives ServiceSupport 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