Miller Electric OM-494 manual Operating Auxiliary Equipment, Maintenance & Troubleshooting

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SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. 120 Volt And 240 Volt Duplex Receptacles
4	6	3	2	5	1

YBe sure equipment connected to the 240 V receptacles is GFCI-pro- tected.

.Generator power is not affected by position of Welder Selector switch.

.4 kVA/kW generator power output is shared by all receptacles.

1240 V 20 A AC Receptacle RC1

2120 V 20 A AC GFCI Receptacle GFCI 1

3240 V 20 A AC Receptacle RC2

4120 V 20 A AC GFCI Receptacle GFCI 2

Receptacles supply 60 Hz single-phase power at weld/power speed.

If a ground fault is detected, the GFCI re- ceptacle(s) circuit opens to disconnect the

faulty equipment and the GFCI Reset but- ton pops out. Check for damaged tools, cords, plugs, etc. connected to the recep- tacle. Press button to reset receptacle and resume operation.

.At least once a month, run engine at

weld/power speed and press Test but- ton to verify GFCI is working properly.

5Circuit Breakers CB1 And CB2

6Circuit Breakers CB3 And CB4

CB1 and CB2 protect RC1 and GFCI 1 from overload. If CB1 or CB2 opens, RC1 does not work. 120 volts may still be present at RC1. If CB2 opens, GFCI 1 does not work. Press button to reset breaker.

CB3 and CB4 protect RC2 and GFCI 2 from overload. If CB3 or CB4 opens, RC2 does not work. 120 volts may still be present at

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RC2. If CB4 opens, GFCI 2 does not work. Press button to reset breaker.

.If a circuit breaker continues to open,

contact Factory Authorized Service Agent.

Maximum output from each 120 volt GFCI receptacle is 2.4 kVA/kW. Maximum output from each 240 volt duplex receptacle half is 4.0 kVA/kW.

Total combined output from all receptacles is 4 kVA/kW.

EXAMPLE: If 12 A is drawn from RC1, only

9 A is available at GFCI 1:

(240 V x 12 A) + (120 V x 9 A) = 4.0 kVA/kW

.Generator power is not affected by weld output.

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

Recycle

engine

fluids.

YStop engine before maintaining.

.See Engine Manual and Maintenance Label for im-

portant start-up, service, and storage information. Service engine more often if used in severe condi- tions.

*To be done by Factory Authorized Service Agent.

Every 8 h

Wipe

Up

Spills.

OIL Full

	Check Fluid	FUEL	Drain Water
			From Fuel
		WATER
	Levels. See		System. See

	Section 5-5.		Section 8-4.

Every 50 h

Clean Air Filter. See Section 8-3.

Clean And

Tighten

Weld

Terminals.

OM-494 Page 32

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Contents Processes DescriptionVisit our website at OM-494191 862P January Dual-Operator Engine Driven Welding GeneratorFrom Miller to You Table of Contents Options and Accessories Warranty Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiquesSymbols And Definitions − Definitions− Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles DescriptionAC Generator Power Fuel ConsumptionExceeding duty cycle can damage unit and void warranty Duty Cycle And OverheatingOverheating Reduce Duty Cycle MinutesCC/DC − Single Mode CC/DC − Dual ModeCV/DC Mode Volt-Ampere Curves− Installation Installing Welding GeneratorActivating The Dry Charge Battery Do not overfill battery cellsRead and follow all instruc ChargerConnecting The Battery Installing Exhaust PipeConnect − Cable Last Top View Tools Needed 1/2Engine Prestart Checks Fuel Do not use gasoline. Gaso Line will damage engineOil Safety Information For Connecting To Weld Output Terminals Weld Output TerminalsUnexpected Weld Output can cause injury or fire Welder a Left Side Welder B Right SideWelder a Left Side Do not exceed machine duty cycleStop engine Do not exceed machine duty cycle Connect electrode holder cables to Elec- trode receptaclesPlace optional Polarity switches in Re Verse position when using CV weld reWhen switch is in Straight position Switches are set correctly. See SectionConnect wire feeder cables to Negative − terminals Connect wire feeder cables to CV recep- taclesBe sure Process Selector switches are Place optional Polarity switch in Re Making Single Operator CC Weld Connections Selecting Weld Cable Sizes 150 ft 200 ft 250 ft350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Put terminalsInstalling Ether Cylinder Optional Ether Starting Aid After installing cylinder, wait atRemote 14 Receptacle Information Socket InformationRemote 14 Receptacle Connections Dual Operator Operation− Operating the Welding Generator Engine ControlsSee -3for weld control descriptions If light goes on, stop engine and check engine beltWeld Controls See Section Do not switch under load or with out- put on Do not switch under loadWeld Control Descriptions See Section CV weld output for MIG is only available− Maintenance & Troubleshooting − Operating Auxiliary EquipmentEvery 100 h Every 200 hEvery 250 h Every 500 hMaintenance Label Servicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hoseServicing Fuel And Lubrication Systems Adjusting Engine Speed Weld/Power 1850Servicing Optional Ether Starting Aid CylinderTo adjust belt tension Checking And Replacing Alternator BeltMax Tools Needed 11/16 Stop engine To check belt tensionResetting Fan Belt Safety Shutdown Inspecting And Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools Needed 3/8Circuit Protection Thermostats TP3 And TP4 Internal − Not ShownTroubleshooting WeldingFactory Authorized Service Agent check main rectifier SR2 Factory Authorized Service Agent check main rectifier SR3Repair or replace wire feeder Formers T5 thru T10, and control board PC1 or PC5Generator Power EngineOM-494 − Electrical Diagrams Circuit Diagram For Welding Generator210 657-A − RUN-IN Procedure WetstackingMent damage may occur Run-In Procedure Using Load Bank 4exceed duty cycle or equip- ment damage may occurCheck oil level frequently dur Ing run-in add oil if neededRun-In Procedure Using Resistance Grid Procedure at less thanBank/grid From flammables− Generator Power Guidelines Has this symbolSelecting Equipment Grounding Generator To Truck Or Trailer FrameGrounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Use ground device as stated Electrical codesApproximate 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 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 311 103 96−SEE -2 101 25−SEE FIG 9104748 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 Service Your distributor also givesSupport 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