Miller Electric Big 40G Description Of Front Panel Controls See Section, Ampere Range Switch

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5-2. Description Of Front Panel Controls (See Section 5-1)

.This unit has a max OCV control circuit that resets Amperage/Voltage Adjust Control R1 to maximum when the arc breaks. When an arc is struck, weld out- put control returns to the R1 front panel or combination front panel/remote control setting. The Amperage/Voltage Adjust control adjusts amperage only when constant current (CC) welding and does not adjust open-circuit voltage. The max OCV control circuit does not function when constant voltage (CV) welding (optional).

1 Ampere Range Switch

YDo not switch under load.

Use switch to select weld amperage range. For most welding applications, use lowest am- perage range possible to help prevent arc out- ages. When using MIG (CV) mode (optional), place switch in maximum position.

2 Amperage/Voltage Adjust Control

Control adjusts amperage within range se- lected by Ampere Range switch. Weld output would be 148 A DC with controls set as shown (50% of 85 to 210 A).

3Amperage/Voltage Adjust Switch (Optional)

Use switch to select front panel or remote am- perage control (see Section 5-3).

For front panel control, place switch in Panel position. For remote control, place switch in Remote position and connect remote control to Remote 14 receptacle RC3 or terminal strip 3T.

4Output (Electrode) Control Switch (Optional)

Use switch to control remote contactor con-

nected to receptacle RC3 or terminal strip 3T (see Sections 4-7 and 4-8).

YWeld output terminals are energized when Output (Electrode) switch is On (Hot) and engine is running.

For weld output, place switch in the On (Hot) position. Open-circuit voltage is present at the weld output terminals whenever engine is run- ning.

For remote output control, place switch in Re- mote position. Open-circuit voltage is present at the weld output terminals when remote con- tactor switch is closed.

5 Process Switch (Optional)

Use switch to select Stick or MIG (CV) weld output. Use Stick for Stick (SMAW) welding. Use MIG (CV) for wire feed processes (MIG, FCAW). If using MIG (CV), place Ampere Range switch in maximum position. To en- sure wire feeder reliability and improve arc starting, unit does not run at idle speed when operated in MIG (CV) mode.

.Place Process switch in Stick position when using optional auxiliary power plant.

6DC Voltmeter (Optional)

7DC Ammeter (Optional)

8Magnetic Shutdown Switch

Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or coolant temperature is too high.

9 Choke Control

Use choke to change engine air-fuel mix.

10 Engine Control Switch

Use switch to start engine, select engine speed, and stop engine.

In Run position, engine runs at weld/power speed. In Run/Idle position, engine runs at idle speed at no load and weld speed with load ap- plied. Turn to run position if using optional aux- iliary power plant.

To Start: Pull choke out. Turn Engine Control switch to Start while pressing Shutdown switch. Release Engine Control switch when engine starts, then release Shutdown switch and push choke in.

.If the engine does not start, let engine come to a complete stop before attempt- ing restart.

To Stop: turn Engine Control switch to Off position.

11Engine Hour Meter

12Polarity And AC Selector Switch (Optional)

YDo not switch under load.

13Battery Charging Warning Light Light goes on if battery is not charging.

14Low Oil Pressure/High Engine Tempera- ture Warning Light

Light goes on if oil pressure is low or coolant temperature is high.

YStop engine and fix trouble if either warning light goes on.

15Fuel Gauge

16Engine Temperature Gauge (Optional)

Normal temperature is 180 - 200° F (81 - 93° C). Stop engine if temperature exceeds 240° F (116° C).

17 Engine Oil Pressure Gauge (Optional)

Normal pressure is 40 psi (276 kPa). Stop en- gine if pressure is below 8 psi (55 kPa).

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Contents
Description OM-477Processes From Miller to You Table of Contents Page ARC Rays can burn eyes and skin Symbol UsageArc Welding Hazards Electric Shock can killEngine Hazards Engine Heat can cause fire Battery Explosion can BlindMoving Parts can cause injury Engine Exhaust Gases can killARC Welding can cause interference Principal Safety StandardsEMF Information Radiation can cause interferenceLES Fumé ES ET LES GAZ peuvent ê tre dangereux Signification des symbolesConsignes DE SÉ Curité Lire Avant Utilisation UN Choc É Lectrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES PIÈ CES Chaudes peuvent provoquer des brû lures gravesLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chaleur DU Moteur peut pro- voquer un incendieConsignes relatives aux stimulateurs cardiaques Principales normes de sé curitéInformation sur les champs é lectromagné tiques LE Soudage À L’ARC risque de provoquer des interfé rencesDefinitions SpecificationsSymbols And Definitions Weld, Power, And Engine SpecificationsFuel Consumption Dimensions, Weights, And Operating AnglesDimensions WeightMinutes 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 100 Volt-Ampere CurvesDC Volts CC/DC Standard AC Amperes CV/DC Models with Optional CV-3 ModuleInstalling Muffler InstallationInstalling Welding Generator Connecting The BatteryTop View Engine Prestart Checks13 mm Full Gasoline Capacity 9 qt 8.5 L 10 100% Duty Cycle Connecting To Weld Output TerminalsSelecting Weld Cable Sizes 100 ft 30 m Or LessStop engine Remote 14 Receptacle RC3 Information Optional, See SectionTerminal Strip 3T Connections Optional Socket InformationFront Panel Controls See Section Operating Welding GeneratorStop engine and fix trouble if either warning light goes on Ampere Range SwitchDo not switch under load Description Of Front Panel Controls See SectionExample Combination remote amperage control Remote Control OptionalVolt Duplex And Optional Gfci Receptacles Operating Auxiliary EquipmentX 10 a + 120 V x 5 a = 3.0 kVA/kW Volt Duplex Receptacle OptionalFront Connecting Optional Auxiliary Power PlantMaintenance and Troubleshooting Maintenance Label Overload Protection Servicing Air CleanerTo Clean air filter Do not clean housing with air hoseStandard filter Changing Engine Oil And FilterStop engine and let cool Standard Oil Filter Cation makes it difficult to changeStop engine and let cool Inspecting And Cleaning Optional Spark Arrestor MufflerChanging Fuel Filter 1850 rpm Max Adjusting Engine Weld/Power SpeedAdjusting Governor Sensitivity Adjusting Engine Idle SpeedTrouble Remedy Adjusting Optional High Altitude CarburetorTroubleshooting WeldingAuxiliary Power See engine manual Coolant temperature gets too high see SectionCheck Engine Control switch, and replace if necessary EngineOM-477 Circuit Diagram For Welding Generator For Standard Models Electrical DiagramsOM-477 193 967-A Grounding Generator To Truck Or Trailer Frame Auxiliary Power GuidelinesSelecting Equipment Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements240 120 Ground Typical Connections To Supply Standby PowerCurrent Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleOM-477 114 113 112 111 110 109 108 107 106 105 104 103 102 101 100 Parts ListIncludes 39 43 Dia Part Description Mkgs Quantity 025 2523 GeneratorGenerator -1 Item Includes 2539CB1,2 139 Control Box w/Components -3 Item Support ServiceYour distributor also gives Miller Electric Mfg. Co Owner’s Record