Miller Electric OM-4409 manual Air Compressor, Optional Battery Charging

Page 64

Trouble

Remedy

 

 

Engine does not run at idle speed.

Turn Process/Contactor switch to any position but Remote On/Off Switch Required-TIG.

 

 

 

Check for obstructed throttle solenoid.

 

 

 

Allow circuit breaker CB14 to reset. Have Factory Authorized Service Agent check throttle solenoid TS1

 

and linkage (see Section 9-8).

 

 

 

Have Factory Authorized Service Agent check idle module PC7, control relays CR3 and CR6, and current

 

transformer CT1.

 

 

Engine uses oil during run-in period;

Dry engine (see Section 14).

wetstacking occurs.

 

 

 

E.

Air Compressor

 

 

 

 

 

Trouble

Remedy

 

 

Air compressor does not operate; no air

Place Air Compressor switch in On position. The air compressor will not start if still under pressure. If

pressure at air shutoff valve.

compressor is turned off, wait for air pressure to bleed off (about 20 seconds) before turning compressor

 

 

on again.

 

 

 

 

 

Reset supplementary protector CB15 (see Section 10-4).

 

 

 

 

 

Check compressor belt tension. Be sure correct belt is used and is properly installed.

 

 

 

 

 

Have Factory Authorized Service Agent check Air Compressor switch S10, control relay CR10, air pres-

 

 

sure switch S11, temperature switch S12, compressor control circuit, and air compressor clutch.

 

 

Air compressor stops after short period

Check compressor oil level (see Section 5-7). Automatic shutdown stops compressor if compressor tem-

of operation.

perature is too high.

 

 

 

 

 

Clean debris from radiator. Automatic shutdown stops compressor if compressor temperature is too high.

 

 

Low air pressure.

Check for leaks in air lines and hoses.

 

 

 

 

 

Adjust compressor air pressure (see Section 10-6).

 

 

 

 

 

Check air compressor air cleaner (see Section 10-3).

 

 

 

 

 

Have Factory Authorized Service Agent check compressor for rated output.

 

 

High air pressure.

Adjust compressor air pressure (see Section 10-6).

 

 

 

 

 

Be sure control line is connected at regulator valve and inlet valve.

 

 

Pneumatic tools freeze up because of

Install optional air dryer/filter kit (Part No. 195 117).

moisture in compressed air.

 

 

 

Oil in air from compressor.

Check compressor oil level (see Section 5-7). If oil level is too high, system becomes saturated with oil.

 

 

 

 

 

Change compressor air/oil separator (see Section 10-5).

 

 

 

 

 

Check connections of control lines (see air compressor circuit diagram in Section 12).

 

 

 

 

 

Have Factory Authorized Service Agent check for blocked separator scavenge check valve/filter orifice.

 

 

Oil in compressor air cleaner.

Have Factory Authorized Service Agent verify compressor inlet valve is operating properly.

 

 

 

F.

Optional Battery Charging

 

 

 

 

 

Trouble

Remedy

 

 

No battery charge output; weld output

Place Output Selector switch in 12 Volt Charge or 24 Volt Charge position.

okay.

 

 

 

 

 

 

Check and tighten battery connections if necessary.

 

 

 

 

 

Turn on remote control device or turn Process/Contactor switch to any Weld Terminals Always On

 

 

position (see Section 6-3).

 

 

No battery charge 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, 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, field current regulator board PC1,

 

 

and field excitation circuit.

 

 

 

OM-4409 Page 60

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Contents OM-4409206 ProcessesDescription File Engine DriveFrom Miller to You Table of Contents − Operating Optional Battery Charger − TroubleshootingTroubleshooting Tables − Parts ListSymbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiquesDES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu DES Organes Mobiles peuvent pro voquer des blessures’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicauxSymbols And Definitions − Definitions− Specifications Weld, Power, And Engine SpecificationsAir Compressor Specifications Sound Level TableWeight Dimensions, Weights, And Operating AnglesLifting Eye Weight Rating DC Stick Mode AC Stick Mode OptionalMIG Mode Stick And MIG Volt-Ampere CurvesAC TIG Mode Optional DC TIG ModeTIG Volt-Ampere Curves Fuel Consumption Duty Cycle And Overheating100% 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 Optional Battery Charging Output Curve Air Compressor Output CurveManufacturing Rating Label − Installation Installing Welding GeneratorLocation/Airflow Clearance Grounding1Mounting Welding Generator Supporting The UnitMounting Surface To Bolt Unit In PlaceInstalling Optional Spark Arrestor Muffler Mount the muffler with the clean- out plug to the outsideStop engine and let cool Be sure to tighten rain cap mounting screwActivating The Dry Charge Battery If Applicable Connecting The BatteryDo 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 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 Stick Using Remote Voltage/Amperage ControlExample Combination Remote Amperage Control TIG − Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesAt 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 − Operating Optional Battery Charger Battery Charge ControlsDetermining Battery Charging Current Output Selector SwitchBattery Charge Cable Connections Battery Charging Procedure To control battery charging output using aJump Starting Procedure Charge battery for 10 minutes before jump starting batteryConnect Remote Or Control Device Momentary-On Switch Cables− ENGINE/GENERATOR Maintenance Engine Maintenance LabelRoutine Engine/Generator Maintenance Material Thickness Reference Chart Checking Generator BrushesServicing Engine Air Cleaner Air cleaner primary element canTo clean air filter 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 specifiedServicing Engine Fuel And Lubrication Systems Wipe up spilled fuelTo change oil and filter To drain water from fuel systemEngine/Generator Overload Protection − AIR Compressor Maintenance Air Compressor Maintenance LabelRoutine Air Compressor Maintenance Servicing Compressor Air Cleaner Compressor Air CleanerRemove engine air cleaner cover Reinstall primary element and cover dust ejector downCompressor Overload Protection See -8for engine/genera- tor overload protectionServicing Air Compressor To change compressor oil and filterEngine oil drain and compressor oil To replace air/oil separatorAdjusting Compressor Air Pressure Troubleshooting Tables − TroubleshootingWelding 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 Wetstacking − RUN-IN ProcedureWelding Generator Run-In Procedure Using Load Bank From flammablesOutput and do not exceed duty 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 Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated in electrical codes Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-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 − Guidelines for TIG Welding Gtaw Positioning The TorchTorch Movement During Welding Tungsten Without Filler RodWelding direction Form pool Tilt torch Tungsten With Filler RodPositioning Torch Tungsten For Various Weld Joints Butt Weld And Stringer Bead Joint Lap Joint Corner Joint− Parts List Hardware is common and not available unless listed133 148 147 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 Your distributor also gives ServiceSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor 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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