Miller Electric 400P, 500 X manual Wiring Harnesses

Page 92

.Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components sepa- rately or as part of the associated wiring harness.

Item

Dia.

 

Part

Description

Quantity

No.

Mkgs.

 

No.

 

 

 

 

Wiring Harnesses

 

 

 

 

 

 

 

 

 

. . . . . . . .

. . . . . . . .

. . . .

215054 . .

Harness, control box, CC weld control (includes)

. . .

1

. . . . . . . .

SR1, SR2 . .

035704 . .

Rectifier, Integ Bridge 40. Amp 800v

. . .

2

. . . . . . . .

. D1/C1 . . . 189701 . .

Diode/Capacitor Board,

1

. . . . . . . .

. . RC4 . . . . 047483 . .

Conn, Rect Univ 084 15p/S 3row Rcpt Cable/Panel Lkg

. . .

1

CB11, CB12, CB13 . . 139266 . .

Supplementary Protector, Man Reset 1p 15a 250vac

. . .

3

. . . . . . . .

. . CR7

. . . . 188636 . .

Relay, Ocv Control

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

148850 . .

Socket, Relay 5 Pin

. . .

1

. . . . . . . .

. . . S6 .

. . . .

011622 . .

Switch, Tgl 3pdt 15a 125vac On−none−on Spd Term

. . .

1

. . . . . . . .

. . . S5 .

. . . .

011609 . .

Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

211292 . .

Conn, Pack 4p 1row Female

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

211293 . .

Conn, Pack Terminal Position Assurance(Lock)

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

164617 . .

Clip, Wiring Straight

. . .

3

. . . . . . . .

. . . S2 .

. . . .

021467 . .

Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

150316 . .

Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg

. . .

5

. . . . . . . .

. . RC3 . . . . 158466 . .

Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg

. . .

1

. . . . . . . .

. . RC1

. . . . 135133 . .

Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

215377 . .

Harness, control box, CV weld control (includes)

. . .

1

CB11, CB12, CB13 . . 139266 . .

Supplementary Protector, Man Reset 1p 15a 250vac

. . .

3

. . . . . . . .

. . SR1

. . . . 035704 . .

Rectifier, Integ Bridge 40. Amp 800v

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

148850 . .

Socket, Relay 5 Pin

. . .

1

. . . . . . . .

. . RC4 . . . . 047483 . .

Conn, Rect Univ 084 15p/S 3row Rcpt Cable/Panel Lkg

. . .

1

. . . . . . . .

. . RC3 . . . . 158466 . .

Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg

. . .

1

. . . . . . . .

. . RC1

. . . . 135133 . .

Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

150316 . .

Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg

. . .

6

. . . . . . . .

. . . S6 .

. . . .

193234 . .

Switch, Rotary 6 Posn Gold Contacts

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

021467 . .

Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term

. . .

1

. . . . . . . .

. . . S5 .

. . . .

011609 . .

Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr

. . .

1

. . . . . . . .

. D1/C1

. . . 189701 . .

Diode/Capacitor Board,

1

. . . . . . . .

. . . . . . . .

. . . .

193183 . .

Conn, Rect Cinch 18 Pin

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

196602 . .

Plug, Cavity 18,30 Position Cinch Connector

. . .

4

. . . . . . . .

. . . . . . . .

. . . .

196603 . .

Seal, Switch 6 Position Rotary .250 Shaft

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

141450 . .

Conn, Rect Metrmate 10skt 1row Plug Cable Lkg

. . .

1

. . . . . . . .

CB5, CB6 . .

093995 . .

Supplementary Pro, Man Reset 1p 15a 250vac Frict

. . .

2

. . . . . . . .

. . . . . . . .

. . . .

211292 . .

Conn, Pack 4p 1row Female

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

211293 . .

Conn, Pack Terminal Position Assurance(Lock)

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

215013 . .

Harness, weld control CC (includes)

. . .

1

. . . . . . . .

. . PLG3

. . . .

158465 . .

Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

187654 . .

Seal, Wire Univ 12p/S 3row

. . .

1

. . . . . . . .

. . PLG6

. . . .

114063 . .

Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

215207 . .

Harness, weld control CV (includes)

. . .

1

. . . . . . . .

. . PLG6

. . . .

114063 . .

Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg

. . .

1

. . . . . . . .

. . PLG8

. . . .

193184 . .

Conn, Rect Cinch 30 Pin

. . .

1

. . . . . . . .

. PLG13 . . . 147992 . .

Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg

. . .

1

. . . . . . . .

. . PLG3

. . . .

158465 . .

Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

187654 . .

Seal, Wire Univ 12p/S 3row

. . .

1

. . . . . . . .

. . . . . . . .

. . . .

196602 . .

Plug, Cavity 18,30 Position Cinch Connector

. . .

6

OM-4421 Page 86

Page 91 Page 93
Image 92
Page 91 Page 93
Contents OM-4421215 075Q ProcessesDescription File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting Decrot1/07 DirectivesStandards Manufacturer European Contact Notified Body Decrotsound6/05Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiquesDES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu DES Organes Mobiles peuvent pro voquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicauxStd − Definitions− 50 h Std Manufacturer’s Rating Labels Symbols And Definitions Some symbols are found only on export productsDimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Volt-Ampere Curves For CC Models Stick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV Models100% Duty Cycle At 400 Amperes Fuel ConsumptionDuty Cycle And Overheating AC Generator Power Curve Optional Three-Phase Generator Curves12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld Load− Installation Installing Welding GeneratorLocation/Airflow Clearance 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 ChecksConnecting To Weld Output Terminals Stick and TIG WeldingMIG and Fcaw Welding Stop engineConnecting to Weld Selecting Weld Cable Sizes150 ft 200 ft 250 ft 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 Starting Controls To StartEngine Gauges And Meters Weld ControlsExample Combination Remote Amperage Control Stick Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label OM-4421 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See Section14 AC/DC Voltmeter Optional Voltage/Amperage Adjust Switch And Remote 14 ReceptacleElectric shock can kill Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIG− Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesAt least once a month, run en If a SupplementaryClose panel opening if no connections are made to generator Three-Phase Power ConnectionRear Of Panel Supplementary Protector CB2 Supplementary Protector CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 − Maintenance & Troubleshooting Maintenance LabelRoutine Maintenance Checking Generator Brushes Servicing Air Cleaner To clean air filterInspecting And Cleaning Optional Spark Arrestor Muffler Adjusting Engine Speed Weld/Power Speed AdjustmentEngine Speed No Load Standard Model Idle Speed Ad- justmentServicing Fuel And Lubrication Systems To change oil and filterTo replace primary fuel 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 Welding Generator − RUN-IN ProcedureWetstacking From flammables Run-In Procedure Using Load BankKeep exhaust and pipe away Run-In Procedure Using Resistance Grid Specifications section in thisJust generator A/V control so Manual− Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Electrically Bond GeneratorGrounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated in electrical codes Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements 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 Support ServiceYour distributor also gives To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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