Miller Electric OM-494 manual Side Control Panels

Page 70

Item

Dia.

Part

Description

Quantity

No.

Mkgs.

No.

 

 

 

Figure 12-3. Side Control Panels (Continued)

 

 

 

 

 

 

. . 24

. . . . . . . .

. . . . 039 046

. . TERMINAL, pwr output black (consisting of)

. . . 2

. . . . . .

. . . . . . . .

. . . . 039 045

. . . . TERMINAL BOARD, black

. . . 1

. . . . . .

. . . . . . . .

. . . . 039 044

. . . . BUS BAR, term bd

. . . 1

. . . . . .

. . . . . . . .

. . . . 601 976

. . . . SCREW, 500-13 x 1.50 hexhd

. . . 1

. . . . . .

. . . . . . . .

. . . . 601 880

. . . . NUT, 500-13 x .75 hex .31H

. . . 1

. . 25

. . . . . . . .

. . . . 192 494

. . BUS BAR, connecting

. . . 2

. . 26

. . . . . . . .

. . . . 192 493

. . STAND-OFF, bus bar

. . . 6

. . 27 C2,4,5,21,22,23 . 136 736

. . CAPACITOR, cer disc .1uf 500VDC

. . . 6

. . . . . .

. . . . . . . .

. . . . 192 336

. . HARNESS, wiring unit welder B (right) (consisting of)

. . . 1

. . 28

. . . 4T . . . . . 190 210

. . . . BLOCK, term 5-3-3

. . . 1

. . 29 . . CB6

. . . . 139 266

. . . . CIRCUIT BREAKER, man reset

. . . 1

. . 30 . . RC9

. . . . 134 735

. . . . CONNECTOR, circ MS/CPC 14skt

. . . 1

. . 31 . . PC7

. . . . 181 261

. . . . CIRCUIT CARD ASSEMBLY, filter

. . . 1

. . . . . .

. PLG24

. . . 115 094

. . . . HOUSING, plug and sockets

. . . 1

. . . . . .

. PLG22

. . . 168 847

. . . . HOUSING, plug pins and sockets

. . . 1

. . . . . .

. PLG23

. . . 152 249

. . . . HOUSING, plug pins and sockets

. . . 1

. . . . . .

. PLG21

. . . 135 556

. . . . HOUSING, plug pins and sockets

. . . 1

. . . . . .

. . . . . . . .

. . . . 188 512

. . . . SEAL, wire univ 6P/S 3 row

. . . 1

. . . . . .

. . . . . . . .

. . . . 192 337

. . HARNESS, wiring unit welder A (left) (consisting of)

. . . 1

. . . . . .

. . . 3T . . . . . 190 210

. . . . BLOCK, term 5-3-3

. . . 1

. . . . . .

. . CB5

. . . . 139 266

. . . . CIRCUIT BREAKER, man reset

. . . 1

. . . . . .

. . RC8

. . . . 134 735

. . . . CONNECTOR, circ MS/CPC 14skt

. . . 1

. . . . . .

. . PC3

. . . . 181 261

. . . . CIRCUIT CARD ASSEMBLY, filter

. . . 1

. . . . . .

. PLG14

. . . 115 094

. . . . HOUSING, plug and sockets

. . . 1

. . . . . .

. . PLG6

. . . . 168 847

. . . . HOUSING, plug pins and sockets

. . . 1

. . . . . .

. . PLG3

. . . . 152 249

. . . . HOUSING, plug pins and sockets

. . . 1

. . . . . .

. PLG13

. . . 135 556

. . . . HOUSING, plug pins and sockets

. . . 1

. . . . . .

. . . . . . . .

. . . . 188 512

. . . . SEAL, wire univ 6P/S 3 row

. . . 1

. . 32

. . . . . . . .

. . . . 165 316

. . STAND-OFF, No. 6-32 x .875 lg .312 hex nyl

. . . 6

. . . . . .

. . . . . . . .

. . . . 145 217

. . SCREW, K40 x 12 pan hd phl stl pld slftpg

. . . 6

. . 33

. . . . . . . .

. . ♦059 773

. . HANDLE, switch

. . . 2

. . 34

. . . . . . . .

. . ♦010 647

. . PIN, spring

. . . 2

. . . . . .

. . . . . . . .

. . ♦091 067

. . SWITCH, polarity

. . . 2

. . . . . .

. . . . . . . .

. . ♦168 077

. . CONNECTOR, tw lk insul fem (Dinse-type) to output stud

. . . 6

. . . . . .

. . . . . . . .

. . ♦199 123

. . LABEL, component identification master polarity

. . . 1

. . . . . .

. . . . . . . .

. . ♦199 124

. . LABEL, component identification slave polarity

. . . 1

. . 35

PL2, PL3 . . 159 522

. . LED, yellow 2.1v 20 ma 45.0 mcd panel mtg .250 hole

. . . 2

. . 36

. . . . . . . .

. . . . 159 036

. . LENS, led clear panel mtg

. . . 2

+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label individually or as part of Label Kit 193 501

*Recommended Spare Parts.

♦OPTIONAL

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-494 Page 66

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Page 69 Page 71
Contents Visit our website at OM-494191 862P January ProcessesDescription 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 EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures ’AIR Comprimé peut provoquer des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiquesSymbols And Definitions − DefinitionsDimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications DescriptionAC Generator Power Fuel ConsumptionOverheating Exceeding duty cycle can damage unit and void warrantyDuty Cycle And Overheating Reduce Duty Cycle MinutesCV/DC Mode CC/DC − Single ModeCC/DC − Dual Mode Volt-Ampere Curves− Installation Installing Welding GeneratorRead and follow all instruc Activating The Dry Charge BatteryDo not overfill battery cells ChargerConnect − Cable Last Connecting The BatteryInstalling Exhaust Pipe Top View Tools Needed 1/2Fuel Do not use gasoline. Gaso Line will damage engine Engine Prestart ChecksOil Unexpected Weld Output can cause injury or fire Safety Information For Connecting To Weld Output TerminalsWeld Output Terminals 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 receptaclesWhen switch is in Straight position Place optional Polarity switches in ReVerse position when using CV weld re 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 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Selecting Weld Cable Sizes150 ft 200 ft 250 ft Put terminalsRemote 14 Receptacle Information Installing Ether Cylinder Optional Ether Starting AidAfter installing cylinder, wait at Socket InformationRemote 14 Receptacle Connections Dual Operator OperationSee -3for weld control descriptions − Operating the Welding GeneratorEngine Controls If light goes on, stop engine and check engine beltWeld Controls See Section Weld Control Descriptions See Section Do not switch under load or with out- put onDo not switch under load CV weld output for MIG is only available− Maintenance & Troubleshooting − Operating Auxiliary EquipmentEvery 250 h Every 100 hEvery 200 h Every 500 hMaintenance Label To clean air filter Servicing Air CleanerBy the warranty Do not clean housing with air hoseServicing Fuel And Lubrication Systems Servicing Optional Ether Starting Aid Adjusting Engine SpeedWeld/Power 1850 CylinderMax Tools Needed 11/16 To adjust belt tensionChecking And Replacing Alternator Belt 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 WeldingRepair or replace wire feeder Factory Authorized Service Agent check main rectifier SR2Factory Authorized Service Agent check main rectifier SR3 Formers T5 thru T10, and control board PC1 or PC5Generator Power EngineOM-494 − Electrical Diagrams Circuit Diagram For Welding Generator210 657-A Wetstacking − RUN-IN ProcedureMent damage may occur Check oil level frequently dur Run-In Procedure Using Load Bank4exceed duty cycle or equip- ment damage may occur Ing run-in add oil if neededBank/grid Run-In Procedure Using Resistance GridProcedure at less than From flammablesSelecting Equipment − Generator Power GuidelinesHas this symbol Grounding Generator To Truck Or Trailer FrameEarth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated Electrical codesIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? 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 Your distributor also gives ServiceSupport For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s
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