Miller Electric OM-4409 manual Troubleshooting Tables, Welding

Page 61

SECTION 11 − TROUBLESHOOTING

11-1. Troubleshooting Tables

A. Welding

Trouble

Remedy

 

 

No weld output; generator power output

Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote

okay at ac receptacles.

On/Off Switch Required position and connect remote contactor to Remote 14 receptacle RC14 (see Sec-

 

tions 5-10and 6-1).

 

 

 

Check position of Ampere Range switch.

 

 

 

Check position of optional Output Selector switch (see Section 8-1).

 

 

 

Reset supplementary protector CB11 (see Section 9-8).

 

 

 

Reset supplementary protector CB5 (see Section 9-8). Check for faulty remote device connected to

 

RC14.

 

 

 

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-10).

 

 

 

Have Factory Authorized Service Agent check connector board PC6 and connections.

 

 

 

Check fuse F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check

 

brushes and slip rings, field excitation circuit, field current regulator board PC1, and the rotor.

 

 

No weld output or generator power

Disconnect equipment from generator power receptacles during start-up.

output.

 

 

 

 

Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent

 

check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

 

 

 

Reset supplementary protector CB12 (see Section 9-8).

 

 

 

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

 

 

Erratic weld output.

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.

 

 

High weld output.

Check position of Ampere Range switch and Voltage/Amperage Adjust control.

 

 

 

Check engine weld/power speed, and adjust if necessary (see Section 9-6).

 

 

 

Have Factory Authorized Service Agent check field current regulator board PC1.

 

 

Voltage/Amperage control does not

Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere

work when welding in Stick mode.

Range switch in highest range.

 

 

Low weld output.

Check engine weld/power speed, and adjust if necessary (see Section 9-6).

 

 

 

Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent

 

check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

 

 

Electrode sticks to the workpiece more

Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8).

frequently during low voltage (short arc

Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.

length) conditions.

 

 

 

 

Have Factory Authorized Service Agent check optional battery charging relay CR7.

 

 

Low open-circuit voltage.

Check engine weld/power speed, and adjust if necessary.

 

 

No remote fine amperage or voltage

Place Panel/Remote Switch in Remote position.

control.

 

 

 

 

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-10).

 

 

 

Repair or replace remote control device.

 

 

OM-4409 Page 57

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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 peu’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion 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 TableWeight Dimensions, Weights, And Operating AnglesLifting Eye Weight Rating AC Stick Mode Optional DC Stick ModeMIG Mode Stick And MIG Volt-Ampere CurvesAC TIG Mode Optional DC TIG ModeTIG Volt-Ampere Curves Duty Cycle And Overheating Fuel Consumption100% Duty Cycle At 500 Amperes 40% Duty Cycle At 600 AmperesGenerator AC Power Curve 12 kVA/kW Single-Phase AC Output No Weld Load Optional 3-Phase Generator Power Curves20 kVA/kW Three-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 batterySwitch may be locked using a customer-supplied padlock Using The Optional Battery Disconnect SwitchStop engine Engine/Compressor Prestart Checks Stick And TIG Welding Connecting To Weld Output TerminalsMIG And Fcaw Welding Selecting Weld Cable Sizes Connecting to weld Output terminals150 ft 200 ft 250 ft 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 Stick Using Remote Voltage/Amperage ControlExample Combination Remote Amperage Control TIG Volt And 240 Volt Receptacles − Operating Auxiliary EquipmentAt least once a month, run en Is working properlyConnecting To Optional AC Power Plant 240 V 15 a AC South African Receptacle RC1 Optional Generator Power ReceptaclesSupplementary Protector CB2 Supplementary Protector CB3 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 Troubleshooting Tables − TroubleshootingWelding 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 Wetstacking − RUN-IN ProcedureWelding Generator 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 Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame 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 Preparing Tungsten For AC Welding Preparing Tungsten For DC Electrode Negative Dcen WeldingAmperage Range Gas Type Polarity 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 Your distributor also gives ServiceSupport 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

OM-4409 specifications

The Miller Electric OM-4409 is a remarkable welding machine designed for both professional welders and enthusiastic hobbyists. Known for its reliability and efficiency, the OM-4409 stands out in the industrial landscape due to its advanced features and innovative technologies.

One of the main features of the OM-4409 is its impressive power output. With a rated output of 400 amps, it is capable of tackling a variety of welding applications, including MIG, TIG, and stick welding. This versatility allows users to switch between welding processes depending on the project requirements while ensuring consistent quality and performance.

The machine incorporates advanced inverter technology, which enhances its overall efficiency. Inverter technology allows for a compact design without sacrificing performance. The OM-4409 weighs significantly less than traditional transformer-based machines, making it more portable and easier to transport. Additionally, the inverter technology ensures that energy consumption is kept to a minimum, reducing operational costs.

Another notable characteristic of the Miller Electric OM-4409 is its user-friendly interface. The intuitive control panel provides easy access to settings and adjustments, allowing welders to fine-tune the machine to their specific needs. The digital display shows crucial parameters such as voltage, amperage, and wire feed speed, enabling welders to monitor their progress in real-time effectively.

Safety is paramount in industrial applications, and the OM-4409 does not disappoint. It is equipped with advanced safety features, including thermal overload protection and fault indication systems. These features ensure that the machine operates within safe limits, protecting both the user and the equipment.

The OM-4409 also boasts a robust build quality, designed to withstand the rigors of daily use in demanding environments. Its durable construction ensures longevity, minimizing maintenance and downtime.

In summary, the Miller Electric OM-4409 welding machine is a powerhouse that combines power, efficiency, and user-friendliness. With its inverter technology, versatility across various welding processes, advanced safety features, and robust design, it represents an excellent investment for any welding professional looking to enhance their capabilities. Whether for heavy-duty industrial applications or intricate metalwork, the OM-4409 delivers unmatched performance and reliability.
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