Miller Electric OM-494 manual Weld Control Descriptions See Section, Do not switch under load

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6-3. Weld Control Descriptions (See Section 6-2)

1 Welder Selector Switch

3 Arc Force (Dig) Control

6 Weld Meters

Use switch to select Dual Operator or Single Operator welding mode.

Place switch in Welder A/Welder B (dual oper- ator) position for CC and CV output from Weld- er A (left) and Welder B (right) weld output ter- minals. Control the weld output from the termi- nals on each side using the weld controls on that same side.

Place switch in Welder B (single operator) position for CC weld output from Welder B (right) weld output terminals only. CV weld out- put terminals on both sides do not work when unit is in Single Operator mode.

.Welder A (left) weld output terminals are disabled in Single Operator mode. Con- nect only to Welder B (right) terminals for Single Operator operation.

.When in single Operator mode, only CC weld output is available. Welder A (left) and Welder B (right) side CV weld output terminals are disabled in Single Operator mode. (see Section 5-8).

2 Process Selector Switch

Use switch to select output for weld process. If switch is in Stick/Tig position, place Welder Selector switch in Welder A/Welder B or Weld- er B Position. If switch is in MIG position, place Welder Selector switch in Welder A/Welder B position only.

.CV weld output for MIG is only available

when Welder Selector switch is in Welder A/Welder B position. All weld output stops if either Process Selector switch is placed in MIG position when Welder Selector switch is in Welder B position.

.Place optional Polarity switch in Reverse

position when using CV weld output. There is no CV weld output when Polarity switch is in Straight position.

YDo not switch under load or with out- put on.

Use control to automatically increase amper- age as arc length is decreased to assist in arc starts and reduce the chance of the electrode sticking in the puddle. Turn clockwise to in- crease short-circuit amperage. Set at mini- mum for TIG welding.

4 Hot Start Switch

Use switch to disable hot start circuit. Turn switch On for Stick (SMAW) and Submerged Arc (SAW) Welding, and Air Carbon Arc Cut- ting and Gouging (CAC-A). Turn switch Off for TIG (GTAW) welding.

When switch is in On position, higher short-cir- cuit amperage helps arc starting. After arc starts, the front panel or remote Amperage/ Voltage control setting determines weld am- perage.

.The hot start circuit does not function when constant voltage (CV) welding.

5 Amperage/Voltage Control

When Process Selector switch is in the Stick/ TIG position, turn control clockwise to in- crease amperage. Read amperage from outer scale of control. The Amperage/Voltage con- trol adjusts amperage only when constant cur- rent (CC) welding and does not adjust open- circuit voltage.

When Process Selector switch is in the MIG position, turn control clockwise to increase voltage. Voltmeter value changes as control knob is turned. Control can be adjusted while welding.

.When Welder Selector switch is in Welder

B position (single operator mode), weld amperage is two times the value selected by the Amperage/Voltage control. For ex- ample, if Amperage/Voltage control is set to 250 A, weld output is actually 500A.

With Process Selector switch in the Stick/Tig position, meters read 0 (zero) with contactor off. Meters display actual output voltage and amperage with contactor on.

With Process Selector switch in the MIG posi- tion, voltmeter displays preset voltage with contactor off. Voltmeter and ammeter display actual output voltage and amperage with con- tactor on.

7 High Temperature Shutdown Light

Light goes on and weld output stops if weld rectifier gets too warm. Let unit cool before welding.

8Remote Amperage/Voltage Control Switch

For front panel control, place switch in Panel position. For remote control, place switch in Remote position, and connect remote device (see Section 5-17).

9 Output (Contactor) Switch

For front panel control of output, place switch in On (Hot) position. For remote control of out- put, place switch in Remote position, and con- nect remote device (see Section 5-17).

YWeld output terminals are energized when Output (Contactor) switch is On and engine is running.

10 Polarity Switch (Optional)

YDo not switch under load.

Use switch to change polarity of weld output (see Sections 5-7thru 5-14).

.Place optional Polarity switch in Reverse

position when using CV weld receptacle. There is no CV weld output when switch is in Straight position.

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Contents Dual-Operator Engine Driven Welding Generator ProcessesDescription Visit our website at OM-494191 862P JanuaryFrom Miller to You Table of Contents Options and Accessories Warranty Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures graves’AIR Comprimé peut provoquer des blessures ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions Symbols And DefinitionsDescription − SpecificationsWeld, Power, And Engine Specifications Dimensions, Weights, And Operating AnglesFuel Consumption AC Generator PowerReduce Duty Cycle Minutes Exceeding duty cycle can damage unit and void warrantyDuty Cycle And Overheating OverheatingVolt-Ampere Curves CC/DC − Single ModeCC/DC − Dual Mode CV/DC ModeInstalling Welding Generator − InstallationCharger Activating The Dry Charge BatteryDo not overfill battery cells Read and follow all instrucTop View Tools Needed 1/2 Connecting The BatteryInstalling Exhaust Pipe Connect − Cable LastOil Engine Prestart ChecksFuel Do not use gasoline. Gaso Line will damage engine Welder a Left Side Welder B Right Side Safety Information For Connecting To Weld Output TerminalsWeld Output Terminals Unexpected Weld Output can cause injury or fireDo not exceed machine duty cycle Welder a Left SideConnect electrode holder cables to Elec- trode receptacles Stop engine Do not exceed machine duty cycleSwitches are set correctly. See Section Place optional Polarity switches in ReVerse position when using CV weld re When switch is in Straight positionConnect wire feeder cables to CV recep- tacles Connect wire feeder cables to Negative − terminalsBe sure Process Selector switches are Place optional Polarity switch in Re Making Single Operator CC Weld Connections Put terminals Selecting Weld Cable Sizes150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mSocket Information Installing Ether Cylinder Optional Ether Starting AidAfter installing cylinder, wait at Remote 14 Receptacle InformationDual Operator Operation Remote 14 Receptacle ConnectionsIf light goes on, stop engine and check engine belt − Operating the Welding GeneratorEngine Controls See -3for weld control descriptionsWeld Controls See Section CV weld output for MIG is only available Do not switch under load or with out- put onDo not switch under load Weld Control Descriptions See Section− Operating Auxiliary Equipment − Maintenance & TroubleshootingEvery 500 h Every 100 hEvery 200 h Every 250 hMaintenance Label Do not clean housing with air hose Servicing Air CleanerBy the warranty To clean air filterServicing Fuel And Lubrication Systems Cylinder Adjusting Engine SpeedWeld/Power 1850 Servicing Optional Ether Starting AidStop engine To check belt tension To adjust belt tensionChecking And Replacing Alternator Belt Max Tools Needed 11/16Resetting Fan Belt Safety Shutdown Reinstall cleanout plug Tools Needed 3/8 Inspecting And Cleaning Optional Spark Arrestor MufflerThermostats TP3 And TP4 Internal − Not Shown Circuit ProtectionWelding TroubleshootingFormers T5 thru T10, and control board PC1 or PC5 Factory Authorized Service Agent check main rectifier SR2Factory Authorized Service Agent check main rectifier SR3 Repair or replace wire feederEngine Generator PowerOM-494 Circuit Diagram For Welding Generator − Electrical Diagrams210 657-A Ment damage may occur − RUN-IN ProcedureWetstacking Ing run-in add oil if needed Run-In Procedure Using Load Bank4exceed duty cycle or equip- ment damage may occur Check oil level frequently durFrom flammables Run-In Procedure Using Resistance GridProcedure at less than Bank/gridGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesHas this symbol Selecting EquipmentUse ground device as stated Electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/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 = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible311 103 96−SEE -2 101 25−SEE FIG 910 − Parts List4748 57−SEE FIG 78−SEE FIG Item Dia Part Description Quantity Mkgs 189 Front Panel Front Panel -1Item Side Control Panels − Welder B Right Side Shown Side Control Panels -1Item Side Control Panels Generator Rectifier Assembly OM-494 Page Support ServiceYour distributor also gives 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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