Miller Electric OM-4409 manual Connecting To Optional AC Power Plant

Page 41

7-2. Connecting To Optional AC Power Plant

Single-Phase Power Connection

1

2

.Do not weld while using optional ac power plant.

.Place Process/Contactor switch in

Weld Terminals Always On - Stick position when using optional ac power plant (see Section 6-3).

Single-Phase Generator Power

1 120/240 V 50 A Receptacle RC5

RC5 is connected to the optional ac power plant and supplies 60 Hz single- phase power at weld/power speed. Maximum output from RC5 is 12 kVA/ kW. Power available at RC5 is reduced when welding.

2 Supplementary Protector CB7

Three-Phase Power Connection

! Close panel opening if no connections are made to power plant.

AC

Single

Three

Phase

Phase

Output

 

1

3

Volts

120/240

240

 

 

 

Amps

50

48

KVA/KW

12

20

Frequency

60 Hz

Engine Speed

1850 RPM

 

 

 

Lead 42 connects to GROUND stud on front of unit.

Jumper 42 is connected to 90 at factory.

93

Supplementary protector CB7 protects single-phase receptacle RC5 and the load wires from overload. If CB7 opens, all generator ac output stops and the receptacle does not work.

Three-Phase Generator Power ! Stop engine.

! Power and weld outputs are live at the same time. Disconnect or insulate unused cables.

.Have qualified person install ac- cording to circuit diagram and Generator Power Guidelines (see Section 16).

Remove power panel mounting screws. Tilt panel forward.

Remove plug before inserting leads. Reinstall bushing.

5

6

7

9

8

Rear Of Panel

91

92

93

240V

120V

1-Phase

120V

 

 

240V

240V

3-Phase

 

240V

 

 

91

3

Lead 93

 

 

 

4

Lead 92

 

 

90

5

Lead 91

4

 

92

6

Lead 42 (Circuit Grounding Lead)

 

 

7

Lead 90 (Neutral)

 

 

 

8

Isolated Neutral Terminal

3

 

 

9

Jumper Lead 42

2

 

 

10

Grounding Terminal

 

 

Jumper 42 is connected to lead 90 at

12

 

 

 

 

factory. Jumper 42 may be discon-

 

 

 

nected from neutral to meet applicable

 

 

 

electrical codes.

10

 

 

Lead 42 connects to front panel

 

 

Ground stud.

 

 

 

 

 

 

11

User-Supplied Leads

11

 

 

12

Supplementary Protector CB7

 

 

 

User Terminals

 

 

 

 

! Close

panel

Connect user-supplied leads to termi-

nals on CB7 and to the isolated neutral

opening

if

no

terminal and grounding terminal as

connections

necessary.

are made

to

 

 

power plant.

 

. Supplementary protector CB7 pro-

tects single-phase receptacle RC5 and the load wires from overload. If CB7 opens, all ac power plant

Tools Needed: output stops and the receptacle does not work.

Reinstall power panel.

Ref. 197 399 / 802 332-B

OM-4409 Page 37

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Contents Processes OM-4409206Description File Engine DriveFrom Miller to You Table of Contents − Troubleshooting − Operating Optional Battery ChargerTroubleshooting Tables − Parts ListArc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsBuildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosionCompressed Air Hazards Engine HazardsHOT Parts can cause burns and injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer Indique des instructions spécifiquesLES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent pro voquer des blessures ’EXPLOSION DE LA Batterie peuRisque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures DES Organes Mobiles peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutPrincipales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF En ce qui concerne les implants médicaux− Definitions Symbols And DefinitionsWeld, Power, And Engine Specifications − SpecificationsAir Compressor Specifications Sound Level TableLifting Eye Weight Rating Dimensions, Weights, And Operating AnglesWeight AC Stick Mode Optional DC Stick ModeMIG Mode Stick And MIG Volt-Ampere CurvesTIG Volt-Ampere Curves DC TIG ModeAC TIG Mode Optional Duty Cycle And Overheating Fuel Consumption100% Duty Cycle At 500 Amperes 40% Duty Cycle At 600 AmperesGenerator AC Power Curve 20 kVA/kW Three-Phase AC Output No Weld Load Optional 3-Phase Generator Power Curves12 kVA/kW Single-Phase AC Output No Weld Load Air Compressor Output Curve Optional Battery Charging Output CurveManufacturing Rating Label Installing Welding Generator − InstallationLocation/Airflow Clearance Grounding1Supporting The Unit Mounting Welding GeneratorMounting Surface To Bolt Unit In PlaceMount the muffler with the clean- out plug to the outside Installing Optional Spark Arrestor MufflerStop engine and let cool Be sure to tighten rain cap mounting screwConnecting The Battery Activating The Dry Charge Battery If ApplicableDo not overfill battery cells Reinstall cover after connecting batteryStop engine Using The Optional Battery Disconnect SwitchSwitch may be locked using a customer-supplied padlock Engine/Compressor Prestart Checks MIG And Fcaw Welding Connecting To Weld Output TerminalsStick And TIG Welding 150 ft 200 ft 250 ft Connecting to weld Output terminalsSelecting Weld Cable Sizes Socket Connecting To Remote 14 Receptacle RC14Open Position Closed Position Connecting To The Air CompressorControls See Section − Operating the Welding GeneratorDescription Of Controls See Section Process/Contactor Switch Settings Process/Contactor SwitchExample Combination Remote Amperage Control TIG Using Remote Voltage/Amperage ControlExample Combination Remote Amperage Control Stick Volt And 240 Volt Receptacles − Operating Auxiliary EquipmentAt least once a month, run en Is working properlyConnecting To Optional AC Power Plant Supplementary Protector CB2 Supplementary Protector CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 Battery Charge Controls − Operating Optional Battery ChargerDetermining Battery Charging Current Output Selector SwitchBattery Charge Cable Connections To control battery charging output using a Battery Charging ProcedureCharge battery for 10 minutes before jump starting battery Jump Starting ProcedureConnect Remote Or Control Device Momentary-On Switch CablesEngine Maintenance Label − ENGINE/GENERATOR MaintenanceRoutine Engine/Generator Maintenance Checking Generator Brushes Material Thickness Reference ChartAir cleaner primary element can Servicing Engine Air CleanerTo clean air filter Optional Keep nozzle 2 in 51 mm from elementReinstall cleanout plug Tools Needed Inspecting/Cleaning Optional Spark Arrestor MufflerDo not set engine speed higher than specified Adjusting Engine SpeedWipe up spilled fuel Servicing Engine Fuel And Lubrication SystemsTo change oil and filter To drain water from fuel systemEngine/Generator Overload Protection Air Compressor Maintenance Label − AIR Compressor MaintenanceRoutine Air Compressor Maintenance Compressor Air Cleaner Servicing Compressor Air CleanerRemove engine air cleaner cover Reinstall primary element and cover dust ejector downSee -8for engine/genera- tor overload protection Compressor Overload ProtectionTo change compressor oil and filter Servicing Air CompressorEngine oil drain and compressor oil To replace air/oil separatorAdjusting Compressor Air Pressure Welding − TroubleshootingTroubleshooting Tables Optional AC Power Plant Standard Generator PowerEngine Air Compressor Optional Battery ChargingCircuit Diagram For Air Compressor − AIR Compressor DiagramCircuit Diagram For Welding Generator − Circuit Diagram221 915−C Welding Generator − RUN-IN ProcedureWetstacking From flammables Run-In Procedure Using Load BankOutput and do not exceed duty Cycle or equipment damage mayRun-In Procedure Using Resistance Grid Flow Of Free Air CFM Through Orifices Of Various Diameters − AIR Compressor TablesSec 15 sec 21 sec Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment How Much Power Does Equipment Require? Grounding When Supplying Building SystemsUse ground device as stated in electrical codes Amperes x Volts = WattsApproximate 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 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Amperage Range Gas Type Polarity Preparing Tungsten For DC Electrode Negative Dcen WeldingPreparing Tungsten For AC Welding Positioning The Torch − Guidelines for TIG Welding GtawTungsten Without Filler Rod Torch Movement During WeldingWelding direction Form pool Tilt torch Tungsten With Filler RodButt Weld And Stringer Bead Joint Lap Joint Corner Joint Positioning Torch Tungsten For Various Weld JointsHardware is common and not available unless listed − Parts List133 148 147 126121 109 120 122 108 102 103 105 106 107 7273 Dia Part Description Quantity Mkgs 224265 199505 CT1 C1/D1 21 22CB11,CB12,CB13 2724 40 39 Hardware is common Not available unless listedCB2 Fuel Generator -1Item Generator172555 Main Rectifier Assembly 10 9 1516 8281 7371 Air Compressor AssemblyAir Compressor Assembly -1Item Clutch Support ServiceYour distributor also gives 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
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