Miller Electric OM-494 manual Factory Authorized Service Agent check main rectifier SR2

Page 47

Trouble

Remedy

 

 

Low weld output on both sides.

Check engine speed, and adjust if necessary (see Section 8-5).

 

 

 

Check position of Process Selector switch(s) (see Section 6-3).

 

 

 

Increase Amperage/Voltage controls settings.

 

 

 

Have Factory Authorized Service Agent check field current regulator board PC4.

 

 

High weld output on both sides.

Have Factory Authorized Service Agent check field current regulator board PC4.

 

 

Erratic weld output on either side.

Check and tighten connections inside and outside unit.

 

 

 

Be sure connection to work piece is clean and tight.

 

 

 

Use dry, properly stored electrodes.

 

 

 

Remove excessive coils from weld cables.

 

 

 

Check Process Selector switch(s) connections and contacts.

 

 

 

Welder A (left) side: check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have

 

Factory Authorized Service Agent check main rectifier SR2.

 

Welder B (right) side: check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have

 

Factory Authorized Service Agent check main rectifier SR3.

 

 

 

Have Factory Authorized Service Agent check Welder Selector switch S2.

 

 

Low open-circuit voltage on both sides.

Check engine speed, and adjust if necessary (see Section 8-5).

 

 

 

Have Factory Authorized Service Agent check field current regulator board PC4.

 

 

Low open-circuit voltage on either side.

Increase Amperage/Voltage control setting.

 

 

 

Welder A (left) side: check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have

 

Factory Authorized Service Agent check main rectifier SR2.

 

Welder B (right) side: check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have

 

Factory Authorized Service Agent check main rectifier SR3.

 

 

 

Have Factory Authorized Service Agent check main rectifiers SR2 and SR3, synchronization trans-

 

formers T5 thru T10, and control board PC1 or PC5.

 

 

No control of weld output on either

Place A/V Control switch in Panel position, or place switch in Remote position and connect remote

side.

control to remote receptacle RC8 or RC9 (see Sections 5-17and 6-3).

 

 

 

Have Factory Authorized Service Agent check control board PC1 or PC5.

 

 

No voltage control on either side; open-

Repair or replace remote device.

circuit voltage present.

 

 

 

 

Place A/V Control switch in Panel position, or place switch in Remote position and connect remote

 

control to remote receptacle RC8 or RC9 (see Sections 5-17and 6-3).

 

 

 

Check connections to Remote receptacle RC8 and RC9.

 

 

 

Have Factory Authorized Service Agent check control board PC1 or PC5.

 

 

Wire feeder does not work (either side).

Reset Welder A (left) circuit breaker CB5 or Welder B (right) circuit breaker CB6 (see Section 8-10).

 

 

 

Check position of Process Selector switches and Welder Selector switch. All weld output stops if

 

either Process Selector switch is placed in CV position when Welder Selector switch is in Welder B

 

position (see Sections 6-1and 6-3).

 

 

 

Check connections to Remote 14 receptacle RC8 (see Section 5-17).

 

 

 

Place optional Polarity switches in Reverse position. There is no CV weld output when Polarity switch

 

is in Straight position.

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

 

 

 

Repair or replace wire feeder.

 

 

OM-494 Page 43

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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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