Miller Electric OM-4409 manual Standard Generator Power, Optional AC Power Plant

Page 62

Trouble

 

Remedy

 

 

 

Constant speed wire feeder does not

 

Reset supplementary protector(s) CB5 and CB13 (see Section 9-8).

work.

 

 

 

 

 

 

 

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

 

 

 

 

 

Repair or replace wire feeder.

 

 

 

Low CV weld output.

 

Set Ampere Range switch to highest range.

 

 

 

Min or max CV weld output only.

 

Check position of Voltage/Amperage Adjust control and Panel/Remote Switch.

 

 

 

 

 

Repair or replace remote control device.

 

 

 

 

 

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

 

 

 

B. Standard Generator Power

 

Trouble

Remedy

 

 

No generator power output at ac recep-

Reset receptacle supplementary protectors.

tacles; weld output okay.

 

 

 

No generator power or weld output.

Disconnect equipment from generator power receptacles during start-up.

 

 

 

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

 

check integrated rectifier SR1, capacitor C9, diode/capacitor board D1/C1, and the rotor.

 

 

 

Reset supplementary protector CB12. Have Factory Authorized Service Agent check field current regula-

 

tor board PC1 (see Section 10-4).

 

 

 

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

 

 

High output at generator power

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

receptacles.

 

 

 

 

Have Factory Authorized Service Agent adjust field current resistor R3.

 

 

Low output at generator power

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

receptacles.

 

 

 

 

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

 

grated rectifier SR1, resistor R3, and capacitor C9.

 

 

C. Optional AC Power Plant

 

Trouble

Remedy

 

 

No or low output at optional ac power

Place Process/Contactor switch in Weld Terminals Always On - Stick position (see Section 6-3).

plant/receptacle RC5.

 

 

 

 

Reset supplementary protector CB7 (see Section 7-2).

 

 

 

Reset supplementary protector CB5 (see Section 9-8).

 

 

 

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

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board

 

PC1.

 

 

High output at optional ac power plant/

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

receptacle RC5.

 

 

 

 

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

 

 

Erratic output at optional ac power plant/

Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board

receptacle RC5.

PC1.

 

 

OM-4409 Page 58

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Contents Description OM-4409206Processes File Engine DriveFrom Miller to You Table of Contents Troubleshooting Tables − Operating Optional Battery Charger− Troubleshooting − Parts ListElectric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosionEngine Hazards Compressed Air HazardsFire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation Indique des instructions spécifiquesLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu DES Organes Mobiles peuvent pro voquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures ’EMPLOI Excessif peutInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité En ce qui concerne les implants médicauxSymbols And Definitions − DefinitionsAir Compressor Specifications − SpecificationsWeld, Power, And Engine Specifications Sound Level TableLifting Eye Weight Rating Dimensions, Weights, And Operating AnglesWeight MIG Mode DC Stick ModeAC Stick Mode Optional Stick And MIG Volt-Ampere CurvesTIG Volt-Ampere Curves DC TIG ModeAC TIG Mode Optional 100% Duty Cycle At 500 Amperes Fuel ConsumptionDuty Cycle And Overheating 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 Optional Battery Charging Output Curve Air Compressor Output CurveManufacturing Rating Label Location/Airflow Clearance − InstallationInstalling Welding Generator Grounding1Mounting Surface Mounting Welding GeneratorSupporting The Unit To Bolt Unit In PlaceStop engine and let cool Installing Optional Spark Arrestor MufflerMount the muffler with the clean- out plug to the outside Be sure to tighten rain cap mounting screwDo not overfill battery cells Activating The Dry Charge Battery If ApplicableConnecting The Battery 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 Connecting To Remote 14 Receptacle RC14 SocketConnecting To The Air Compressor Open Position Closed Position− Operating the Welding Generator Controls See SectionDescription Of Controls See Section Process/Contactor Switch Process/Contactor Switch SettingsExample Combination Remote Amperage Control TIG Using Remote Voltage/Amperage ControlExample Combination Remote Amperage Control Stick At least once a month, run en − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles 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 Determining Battery Charging Current − Operating Optional Battery ChargerBattery Charge Controls Output Selector SwitchBattery Charge Cable Connections Battery Charging Procedure To control battery charging output using aConnect Remote Or Control Device Momentary-On Switch Jump Starting ProcedureCharge battery for 10 minutes before jump starting battery Cables− ENGINE/GENERATOR Maintenance Engine Maintenance LabelRoutine Engine/Generator Maintenance Material Thickness Reference Chart Checking Generator BrushesTo clean air filter Servicing Engine Air CleanerAir cleaner primary element can Optional Keep nozzle 2 in 51 mm from elementInspecting/Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools NeededAdjusting Engine Speed Do not set engine speed higher than specifiedTo change oil and filter Servicing Engine Fuel And Lubrication SystemsWipe up spilled fuel To drain water from fuel systemEngine/Generator Overload Protection − AIR Compressor Maintenance Air Compressor Maintenance LabelRoutine Air Compressor Maintenance Remove engine air cleaner cover Servicing Compressor Air CleanerCompressor Air Cleaner Reinstall primary element and cover dust ejector downCompressor Overload Protection See -8for engine/genera- tor overload protectionEngine oil drain and compressor oil Servicing Air CompressorTo change compressor oil and filter To replace air/oil separatorAdjusting Compressor Air Pressure Welding − TroubleshootingTroubleshooting Tables Standard Generator Power Optional AC Power PlantEngine Optional Battery Charging Air Compressor− AIR Compressor Diagram Circuit Diagram For Air Compressor− Circuit Diagram Circuit Diagram For Welding Generator221 915−C Welding Generator − RUN-IN ProcedureWetstacking Output and do not exceed duty Run-In Procedure Using Load BankFrom flammables Cycle or equipment damage mayRun-In Procedure Using Resistance Grid − AIR Compressor Tables Flow Of Free Air CFM Through Orifices Of Various DiametersSec 15 sec 21 sec Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Use ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial 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 / 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 − Guidelines for TIG Welding Gtaw Positioning The TorchWelding direction Form pool Tilt torch Torch Movement During WeldingTungsten Without Filler Rod Tungsten With Filler RodPositioning Torch Tungsten For Various Weld Joints Butt Weld And Stringer Bead Joint Lap Joint Corner Joint133 148 147 − Parts ListHardware is common and not available unless listed 126121 109 120 122 108 102 103 105 106 107 7273 Dia Part Description Quantity Mkgs 224265 199505 CT1 21 22 C1/D1CB11,CB12,CB13 Hardware is common Not available unless listed 2724 40 39CB2 Fuel Generator Generator -1Item172555 Main Rectifier Assembly Air Compressor Assembly 10 9 1516 8281 7371Air Compressor Assembly -1Item Clutch Support ServiceYour distributor also gives 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

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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