Miller Electric Big 40G manual Auxiliary Power

Page 36

Trouble

Remedy

 

 

Low or high weld output.

Check control settings.

 

 

 

Place optional Process switch in correct position (see Section 5-1).

 

 

 

Check engine weld/power speed, and adjust if necessary (see Section 7-8).

 

 

 

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

 

 

Low open-circuit voltage.

Place optional Process switch in correct position.

 

 

 

Check engine weld/power speed, and adjust if necessary (see Section 7-8).

 

 

 

Have Factory Authorized Service Agent check field current regulator board PC1 and optional CV-3 regu-

 

lator board PC2.

 

 

Maximum weld output only in each am-

Have Factory Authorized Service Agent check Amperage/Voltage Adjust control R1, capacitor C8,

pere range.

diode D9, integrated rectifier SR4, control relay CR3, field current regulator board PC1, and optional

 

CV-3 regulator board PC2.

 

 

No CV weld output (units with remote

Check connections to Remote 14 receptacle RC3 and terminal strip 3T (see Sections 4-7 and 4-8).

control or CV-3 option only).

 

 

 

 

Repair or replace remote control device.

 

 

 

Have Factory Authorized Service Agent check connector board PC5 and connections.

 

 

Wire feeder does not work (models with

Reset circuit breaker CB3 and/or CB4 (see Section 7-4).

CV-3 option).

 

 

 

 

Check connections to Remote 14 receptacle RC3 and terminal strip 3T (see Sections 4-7 and 4-8).

 

 

 

Repair or replace wire feeder.

 

 

No amperage control (or voltage control

Place Amperage/Voltage Adjust switch in correct position.

on models with CV-3 option).

 

 

 

 

Check connections to Remote 14 receptacle RC3 and terminal strip 3T (see Sections 4-7 and 4-8).

 

 

 

Repair or replace remote control device.

 

 

 

Have Factory Authorized Service Agent check optional CV-3 regulator board PC2.

 

 

Low CV weld output (models with CV-3

Set Ampere Range switch to highest range.

option).

 

 

 

Min or max CV weld output only (models

Check position of Amperage/Voltage Adjust control and Amperage/Voltage Adjust switch.

with CV-3 option).

 

 

 

 

Repair or replace remote control device.

 

 

 

Have Factory Authorized Service Agent check optional CV-3 regulator board PC2.

 

 

B. Auxiliary Power

 

Trouble

Remedy

 

 

No output at auxiliary power ac

Reset circuit breaker CB1 and/or CB2 (see Section 6-1).

receptacles.

 

 

 

 

Disconnect equipment from receptacles during start-up.

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings.

 

 

No or low output at optional auxiliary

Place optional Output (Electrode) Control switch in On (Hot) position, or move switch to Remote posi-

power plant.

tion and connect remote contactor to Remote 14 receptacle RC3 or terminal strip 3T (see Sections

 

4-7, 4-8, and 5-1).

 

 

 

Place optional Amperage/Voltage Adjust switch in Panel position, or move to Remote position and

 

connect remote amperage control to Remote 14 receptacle RC3 or terminal strip 3T (see Sections

 

4-7, 4-8, and 5-1)

 

 

 

Place optional remote amperage control in maximum position (see Section 5-3).

 

 

 

Place optional Process switch in Stick position (see Section 5-1).

 

 

 

Check fuses F1, F2, and F3 and replace as necessary (see Section 6-3).

 

 

 

Check engine weld/power speed, and adjust if necessary (see Section 7-8).

 

 

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Contents
OM-477 ProcessesDescription 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 ConsumptionAC Auxiliary Power Duty Cycle And OverheatingMinutes Welding Minutes Resting Optional AC Power Plant Curves 5 KVA/KW Single-Phase Auxiliary Power Plant No Weld Load12.5 KVA/KW Three-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 MufflerEngine Prestart Checks 13 mm Full Gasoline Capacity 9 qt 8.5 LTop View 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 filterInspecting And Cleaning Optional Spark Arrestor Muffler Changing Fuel FilterStop engine and let cool 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 Auxiliary Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame 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 Service Your distributor also givesSupport Owner’s Record Miller Electric Mfg. Co