Miller Electric OM-4409 manual CB2

Page 93

Item

 

Dia.

 

Part

Description

Quantity

No.

Mkgs.

 

No.

 

 

 

 

Figure 19-3. Panel, Front w/Components (Continued)

 

 

 

 

 

 

 

 

. . . . . . . .

. . .

. . . . .

. .

. . 206809 . .

Harness, Weld Control (includes)

. . . 1

. . . 5

S6 .

. .

. . 193234 . . .

. Switch, Rotary 6 Position Gold Contacts

. . . 1

. . . . . . . .

. . .

. . . . .

. .

. . 197257 . . .

. Guard, Circuit Breaker (For S6 − Not Included w/Harness)

. . . 1

. . . 6

S5 .

. .

. . 011609 . . .

. Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr

. . . 1

. . . . . . . .

. . PLG9

. .

. . 193183 . . .

. Conn, Rect Cinch 18 Pin

. . . 1

. . . . . . . .

. . .

. . . . .

. .

. . 196603 . . .

. Seal, Switch 6 Position Rotary .250 Shaft

. . . 1

. . . . . . . .

. PLG14 . . . 141450 . . .

. Conn, Rect Metrmate 10skt 1row Plug Cable Lkg

. . . 1

. . . . . . . .

. . .

. . . . .

. .

. . 164617 . . .

. Clip,Wiring Straight

. . . 2

. . . . . . . .

. PLG10 . . . 150316 . . .

. Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg

. . . 1

. . . 7 . . . . CB5

. . . . 139266 . . .

. Supplementary Protector, Man Reset 1p 15a 250vac Frict

. . . 1

. . . . . . . .

. .

CB6 . . . . 139266 . . .

. Supplementary Protector, Man Reset 1p 15a 250vac Frict

. . . 1

. . . 8 . .

. . .

. . . . .

. .

. . 202209 . .

Spacer, Nylon .221 Thk

. . . 2

. . . 9 . . . . PC6

. . . . 192995 . .

Circuit Card Assy, Connector/Receptacle

. . . 1

. . . 10 . .

. . .

S1 .

. .

. . 212436 . .

Switch, Ignition 4 Position W/Handle

. . . 1

. . . 11 . .

. . .

S10

. . . . 206624 . .

Switch, Tgl Sptt 6a 125vac (On)−on−(On) Spd Term (Included In Engine

. . . . . . . .

. . .

. . . . .

. .

. . . . . . . . . . . .

Wiring Harness, See Figure Figure 19-2)

. . . 1

. . . 12 . .

. . .

S2 .

. .

. . 021467 . .

Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term (Included In Engine

. . . . . . . .

. . .

. . . . .

. .

. . . . . . . . . . . .

Wiring Harness, See Figure Figure 19-2)

. . . 1

. . . 13 . .

. .

CB1

. . . . 201083 . .

Supplementary Protector, Man Reset 2p 20a 250vac

. . . 1

. . . . . . . .

. . .

. . . . .

. .

. . 201553 . .

Clip, Retaining Circuit Breaker

. . . 1

. . . . . . . .

. . .

. . . . .

. .

. . 201109 . .

Harness, Receptacle Auxillary Power (includes)

. . . 1

. . . 14 . .

. .

CB2

. . . . 093996 . . .

. Supplementary Protector, Man Reset 1p 20a 250vac Frict

. . . 1

. . . 15 . .

. GFCI1

. . . 151981 . . .

. Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi

. . . 1

. . . 16 . .

. .

RC1

. . . . 147632 . . .

. Rcpt,Tw Lk Grd 2p3w 30a 250v *L6−30r

. . . 1

. . . . . . . .

. . .

. . . . .

. .

. . 010146 . . .

. Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole

. . . 2

. . . 17 . .

. .

RC5

. . ♦182954 . .

Rcpt, Str 3p4w 50a 125/250v

. . . 1

. . . 18 . .

. . .

. . . . .

. .

♦025248 . .

Stand-off, Insul .250-20 X 1.2

. . . 1

. . . 19 . .

. . .

. . . . .

. .

♦604102 . .

Connector, Clamp Cable 1.000

. . . 1

. . . 20 . .

. . .

. . . . .

. .

♦197527 . .

Guard, Circuit Breaker

. . . 1

. . . 21 . .

. . .

. . . . .

. .

♦197363 . .

Terminal, Ring Tng Screw Clamp

. . . 3

. . . 22 . .

. .

CB7

. . ♦214926 . .

Supplementary Protector, Man Reset 3p 50a 250vac

. . . 1

. . . 23 . .

. . .

. . . . .

. .

. +215347 . .

Panel, Power

. . . 1

. . . . . . . .

. . .

. . . . .

.

+♦215363 . .

Panel, Generator Power (Full KVA Option)

. . . 1

. . . . . . . .

. .

CT2 . . ♦197433 . .

Transformer, Current Sensing

. . . 1

. . . 24 . .

. . .

. . . . .

. .

♦214927 . .

Boot, Circuit Breaker 1 Pole

. . . 1

. . . 25 . .

. . .

. . . . .

. .

♦197508 . .

Plug, Protective

. . . 1

. . . 26 . .

. . .

. . . . .

. .

♦077440 . .

Bushing, Conduit 1 In

. . . 1

. . . 27 . .

. . .

. . . . .

. .

. . 601836 . .

Nut, 250−20 .50hex .19h Brs

. . . 3

. . . . . . . .

. . .

. . . . .

. .

. . 010915 . .

Washer, Flat .257idx0.640odx.031t Brs

. . . 4

. . . . . . . .

. . .

. . . . .

. .

. . 163167 . .

Washer, Lock .254idx0.489odx.062t Sst Split.250

. . . 2

. . . 28 . .

. .

GRD

. .

. . 083030 . .

Stud, Brs .250−20 X 1.750 W/Hex Collar

. . . 1

. . . 29 . .

. . .

. . . . .

. .

♦209056 . .

Cover, Receptacle W/Gasket

. . . 1

. . . 30 . .

. . .

. . . . .

. .

. . 190861 . .

Label, Warning Electric Shock And Moving Parts Etc

. . . 1

. . . . . . . .

. . .

. . . . .

. .

♦197399 . .

Label, Warning 3 Ph Generator Power

. . . 1

. . . 31 . .

. . .

. . . . .

. .

. . 209056 . .

Cover, Receptacle 2.250 Dia. Lexan

. . . 2

. . . 32 . .

. . .

. . . . .

. .

♦210149 . .

Label, Battery Charge (Switch Position)

. . . 1

. . . . . . . .

. . .

. . . . .

. .

. . . . . . . ♦ . .

Label, Polarity/AC Switch Position

. . . 1

. . . 33 . .

. . .

S12

. .

♦220491 . .

Switch, Polarity/AC

. . . 1

. . . . . . . .

. . .

S13 . . ♦210217 . .

Switch, Battery Charge Assy

. . . 1

. . . 34 . .

. . .

. . . . .

. .

. . 201125 . .

Panel, Mtg Terminal Power Output

. . . 1

. . . 35 . .

PC4, PC5

. . 189744 . .

Circuit Card Assembly, HF

. . . 2

. . . 36 . .

. . .

. . . . .

. .

♦210206 . .

Bracket, Support Switch

. . . 1

. . . 37 . .

. . .

. . . . .

. .

. . 039046 . .

Terminal, Pwr Output Black

. . . 1

. . . . . . . .

. . .

. . . . .

. .

. . 180735 . .

Washer, Output Stud

. . . 2

. . . 38 . .

. . .

. . . . .

. .

. . 134201 . .

Stand−off Support, Pc Card .312/.375w/Post&lock .43

. . . 8

. . . 39 . .

. . .

. . . . .

. .

. . 181169 . .

Spacer, Output Stud

. . . 2

. . . 40 . .

. . .

. . . . .

. .

. . 186621 . .

Boot, Generic Output Stud

. . . 2

OM-4409 Page 89

Page 92 Page 94
Image 93
Page 92 Page 94
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 peuLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque 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 TableDimensions, Weights, And Operating Angles WeightLifting Eye Weight Rating AC Stick Mode Optional DC Stick ModeMIG Mode Stick And MIG Volt-Ampere CurvesDC TIG Mode AC TIG Mode OptionalTIG Volt-Ampere Curves Duty Cycle And Overheating Fuel Consumption100% Duty Cycle At 500 Amperes 40% Duty Cycle At 600 AmperesGenerator AC Power Curve Optional 3-Phase Generator Power Curves 12 kVA/kW Single-Phase AC Output No Weld Load20 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 batteryUsing The Optional Battery Disconnect Switch Switch may be locked using a customer-supplied padlockStop engine Engine/Compressor Prestart Checks Connecting To Weld Output Terminals Stick And TIG WeldingMIG And Fcaw Welding Connecting to weld Output terminals Selecting Weld Cable Sizes150 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 SwitchUsing Remote Voltage/Amperage Control Example Combination Remote Amperage Control StickExample 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 Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Supplementary 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 Troubleshooting TablesWelding 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 − RUN-IN Procedure WetstackingWelding 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 − Generator Power Guidelines Selecting EquipmentGrounding 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 DC Electrode Negative Dcen Welding Preparing Tungsten For AC 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 Service Your distributor also givesSupport 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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