Miller Electric Big 40G manual Connecting To Weld Output Terminals, Selecting Weld Cable Sizes

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4-5. Connecting To Weld Output Terminals

 

Open left side door.

 

1

Bracket

3

Route cables through bracket.

 

 

 

2

Positive (+) Weld Output

 

 

Terminal

2

3

Negative (–) Weld Output Ter-

 

 

minal

 

For Stick welding Direct Current

 

Electrode Positive (DCEP), con-

 

nect work cable to (–) terminal and

 

electrode holder cable to (+)

 

terminal.

For Direct Current Electrode Nega-

Left Sidetive (DCEN), reverse cable connections.

If equipped with optional polarity switch, connect electrode holder cable to Electrode (–) terminal and work cable to Work (+) terminal.

For MIG and FCAW welding with

CV option, connect work cable to

(–) terminal and wire feeder cable to

(+) terminal

Close door.

1

Tools Needed:

3/4 in

 

 

 

 

 

 

 

 

ST-800 162-A

 

 

 

 

 

 

 

 

 

 

 

4-6. Selecting Weld Cable Sizes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Total Cable (Copper) Length In Weld Circuit Not Exceeding

 

 

 

 

 

 

 

 

 

 

 

 

 

Welding

100 ft (30 m) Or Less

150 ft

200 ft

250 ft

300 ft

350 ft

400 ft

 

(45 m)

(60 m)

(70 m)

(90 m)

(105 m)

(120 m)

 

Amperes

 

 

 

 

 

 

 

 

 

 

 

 

 

10 – 60%

60 – 100% Duty

 

 

10 – 100% Duty Cycle

 

 

 

 

Duty Cycle

Cycle

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100

4

4

4

3

2

1

1/0

1/0

 

 

 

 

 

 

 

 

 

 

 

150

3

3

2

1

1/0

2/0

3/0

3/0

 

 

 

 

 

 

 

 

 

 

 

200

3

2

1

1/0

2/0

3/0

4/0

4/0

 

 

 

 

 

 

 

 

 

 

 

250

2

1

1/0

2/0

3/0

4/0

2-2/0

2-2/0

 

 

 

 

 

 

 

 

 

 

 

300

1

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

 

 

 

 

 

 

 

 

 

 

 

350

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

 

 

 

 

 

 

 

 

 

 

 

400

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

2-4/0

 

 

 

 

 

 

 

 

 

 

 

500

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-3/0

 

 

 

 

 

 

 

 

 

 

 

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your

distributor for the mm2 equivalent weld cable sizes.

S-0007-E

OM-477 Page 16

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Contents Description OM-477Processes From Miller to You Table of Contents Page Symbol Usage Arc Welding HazardsElectric Shock can kill ARC Rays can burn eyes and skinEngine Hazards Battery Explosion can Blind Moving Parts can cause injuryEngine Exhaust Gases can kill Engine Heat can cause firePrincipal Safety Standards EMF InformationRadiation can cause interference ARC Welding can cause interferenceSignification des symboles Consignes DE SÉ Curité Lire Avant UtilisationUN Choc É Lectrique peut tuer LES Fumé ES ET LES GAZ peuvent ê tre dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES PIÈ CES Chaudes peuvent provoquer des brû lures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie LA Chute DE L’APPAREIL peut blesserPrincipales normes de sé curité Information sur les champs é lectromagné tiquesLE Soudage À L’ARC risque de provoquer des interfé rences Consignes relatives aux stimulateurs cardiaquesSpecifications Symbols And DefinitionsWeld, Power, And Engine Specifications DefinitionsDimensions, Weights, And Operating Angles DimensionsWeight Fuel ConsumptionMinutes Welding Minutes Resting AC Auxiliary PowerDuty Cycle And Overheating 12.5 KVA/KW Three-Phase Auxiliary Power Plant No Weld Load Optional AC Power Plant Curves5 KVA/KW Single-Phase Auxiliary Power Plant No Weld Load Volt-Ampere Curves DC Volts CC/DC StandardAC Amperes CV/DC Models with Optional CV-3 Module 100Installation Installing Welding GeneratorConnecting The Battery Installing MufflerTop View Engine Prestart Checks13 mm Full Gasoline Capacity 9 qt 8.5 L Connecting To Weld Output Terminals Selecting Weld Cable Sizes100 ft 30 m Or Less 10 100% Duty CycleRemote 14 Receptacle RC3 Information Optional, See Section Terminal Strip 3T Connections OptionalSocket Information Stop engineOperating Welding Generator Front Panel Controls See SectionAmpere Range Switch Do not switch under loadDescription Of Front Panel Controls See Section Stop engine and fix trouble if either warning light goes onRemote Control Optional Example Combination remote amperage controlOperating Auxiliary Equipment Volt Duplex And Optional Gfci ReceptaclesVolt Duplex Receptacle Optional X 10 a + 120 V x 5 a = 3.0 kVA/kWConnecting Optional Auxiliary Power Plant FrontMaintenance and Troubleshooting Maintenance Label Servicing Air Cleaner To Clean air filterDo not clean housing with air hose Overload ProtectionChanging Engine Oil And Filter Stop engine and let cool Standard Oil FilterCation makes it difficult to change Standard filterStop engine and let cool Inspecting And Cleaning Optional Spark Arrestor MufflerChanging Fuel Filter Adjusting Engine Weld/Power Speed 1850 rpm MaxAdjusting Engine Idle Speed Adjusting Governor SensitivityAdjusting Optional High Altitude Carburetor TroubleshootingWelding Trouble RemedyAuxiliary Power Coolant temperature gets too high see Section Check Engine Control switch, and replace if necessaryEngine See engine manualOM-477 Electrical Diagrams Circuit Diagram For Welding Generator For Standard ModelsOM-477 193 967-A Grounding Generator To Truck Or Trailer Frame Auxiliary Power GuidelinesSelecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying 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 xTypical Connections To Supply Standby Power 240 120 GroundSelecting Extension Cord Use Shortest Cord Possible Current Load Watts AmperesOM-477 Parts List 114 113 112 111 110 109 108 107 106 105 104 103 102 101 100Includes 39 43 Dia Part Description Mkgs Quantity 025 Generator 2523Generator -1 Item 2539 IncludesCB1,2 139 Control Box w/Components -3 Item Support ServiceYour distributor also gives Owner’s Record Miller Electric Mfg. Co