Miller Electric OM-494 manual Circuit Protection, Thermostats TP3 And TP4 Internal − Not Shown

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8-10. Circuit Protection

1 2

5

Tools Needed:

3 4

7

8

6

9

YStop engine.

.When a circuit breaker or fuse opens,

it usually indicates a more serious problem exists. Contact Factory Au- thorized Service Agent.

1Fuse F1

2Fuse F2

3Fuse F3

4Fuse F4 Open front panel.

Fuse F1 protects the exciter excitation winding. If F1 opens, there is no weld or generator power output on both sides.

Fuse F2 protects the exciter main field ex- citation winding. If F2 opens, there is no weld output on both sides.

Fuse F3 protects Welder A (left) control board PC1. If F3 opens, Welder A (left) weld output stops.

Fuse F4 protects Welder B (right) control

board PC1. If F4 opens, Welder B (right) weld output stops.

5Circuit Breaker CB5

6Circuit Breaker CB6

7Circuit Breaker CB7

8Circuit Breaker CB8

Circuit Breaker CB5 protects the 24 volt and 115 volt ac output to Welder A (left) re- mote receptacle RC9. If CB5 opens, Weld- er A (left) RC9 24 and 115 volt ac output stops.

Circuit Breaker CB6 protects the 24 volt and 115 volt ac output to Welder B (right) re- mote receptacle RC8. If CB6 opens, Weld- er B (right) RC8 24 and 115 volt ac output stops.

Circuit Breaker CB7 protects field current regulator board PC4. If CB7 opens, weld and generator power output on both sides stops.

Circuit Breaker CB8 protects the generator field flashing circuit. If CB8 opens, weld and

Ref. 802 300 / Ref. 802 292-A

generator power output may continue if generator maintains excitation. Weld and generator power output stops if generator requires field flashing circuit to restore ex- citation.

Press button to reset circuit breaker.

9 Fuses F11, F12, F13, F21, F22, F23

These fuses protect the weld stator wind- ings. If fuse F11, F12, or F13 opens, Welder B (right) side output is erratic or low. If fuse F21, F22, or F23 opens, Welder A (left) side output is erratic or low.

10Thermostats TP3 And TP4 (Internal − Not Shown)

Thermostat TP3 protects Welder A (left) SR2 rectifier and TP4 protects Welder B (right) SR3 rectifier from overheating. If TP3 or TP4 opens, Welder A (left) or Welder B (right) weld output stops and the High Temp. Shutdown light goes on. Wait fifteen minutes for module to cool and thermostat to automatically reset. Reduce amperage, voltage, or duty cycle before welding.

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Contents Description ProcessesVisit our website at OM-494191 862P January Dual-Operator Engine Driven Welding GeneratorFrom Miller to You Table of Contents Options and Accessories Warranty Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions Symbols And DefinitionsWeld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles DescriptionFuel Consumption AC Generator PowerDuty Cycle And Overheating Exceeding duty cycle can damage unit and void warrantyOverheating Reduce Duty Cycle MinutesCC/DC − Dual Mode CC/DC − Single ModeCV/DC Mode Volt-Ampere CurvesInstalling Welding Generator − InstallationDo not overfill battery cells Activating The Dry Charge BatteryRead and follow all instruc ChargerInstalling Exhaust Pipe Connecting The BatteryConnect − Cable Last Top View Tools Needed 1/2Engine Prestart Checks Fuel Do not use gasoline. Gaso Line will damage engineOil Weld Output Terminals Safety Information For Connecting To Weld Output TerminalsUnexpected Weld Output can cause injury or fire Welder a Left Side Welder B Right SideDo not exceed machine duty cycle Welder a Left SideConnect electrode holder cables to Elec- trode receptacles Stop engine Do not exceed machine duty cycleVerse position when using CV weld re Place optional Polarity switches in ReWhen switch is in Straight position Switches are set correctly. See SectionConnect 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 150 ft 200 ft 250 ft Selecting Weld Cable Sizes350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Put terminalsAfter installing cylinder, wait at Installing Ether Cylinder Optional Ether Starting AidRemote 14 Receptacle Information Socket InformationDual Operator Operation Remote 14 Receptacle ConnectionsEngine Controls − Operating the Welding GeneratorSee -3for weld control descriptions If light goes on, stop engine and check engine beltWeld Controls See Section Do not switch under load Do not switch under load or with out- put onWeld Control Descriptions See Section CV weld output for MIG is only available− Operating Auxiliary Equipment − Maintenance & TroubleshootingEvery 200 h Every 100 hEvery 250 h Every 500 hMaintenance Label By the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hoseServicing Fuel And Lubrication Systems Weld/Power 1850 Adjusting Engine SpeedServicing Optional Ether Starting Aid CylinderChecking And Replacing Alternator Belt To adjust belt tensionMax Tools Needed 11/16 Stop engine To check belt tensionResetting 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 TroubleshootingFactory Authorized Service Agent check main rectifier SR3 Factory Authorized Service Agent check main rectifier SR2Repair or replace wire feeder Formers T5 thru T10, and control board PC1 or PC5Engine Generator PowerOM-494 Circuit Diagram For Welding Generator − Electrical Diagrams210 657-A − RUN-IN Procedure WetstackingMent damage may occur 4exceed duty cycle or equip- ment damage may occur Run-In Procedure Using Load BankCheck oil level frequently dur Ing run-in add oil if neededProcedure at less than Run-In Procedure Using Resistance GridBank/grid From flammablesHas this symbol − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer FrameHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Use ground device as stated Electrical codesApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical 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 Service Your distributor also givesSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s