Miller Electric Big 40 CAT manual Overload Protection

Page 54

9-8. Overload Protection

 

 

 

Y Stop engine.

 

 

 

. When a circuit breaker or fuse

 

 

 

 

opens, it usually indicates a

 

 

 

 

more serious problem exists.

 

 

 

 

Contact Factory Authorized

 

 

 

 

Service Agent.

 

 

 

1

Fuse F1

 

 

 

2

Fuse F2

 

 

 

F1 and F2 protect the stator exciter

 

 

 

winding from overload. If F1 opens,

 

 

 

weld and generator power is low or

 

 

 

stops entirely. If F2 opens, weld out-

 

 

 

put is low or stops entirely. 4 kVA/kW

 

 

 

generator power is still available.

 

2

1

3

Circuit Breaker CB4 (Not

 

 

 

 

Shown)

 

 

 

4

Circuit Breaker CB5

 

 

 

 

(CC/CV Models Only)

 

 

 

5

Circuit Breaker CB6

 

 

 

 

(CC/CV Models Only)

 

 

 

6 Circuit Breaker CB10 (Not

 

9

 

 

Shown)

 

8

 

7

Circuit Breaker CB11

 

7

 

 

 

8

Circuit Breaker CB12

 

 

 

 

 

 

9

Circuit Breaker CB13

 

 

 

CB4 protects the welding arc drive

 

 

 

(dig) circuit. If CB4 opens, electrode

 

 

 

may stick to the workpiece more fre-

 

 

 

quently during low voltage (short arc

 

 

 

length) conditions. CB4 automatical-

 

 

 

ly resets when the fault is corrected.

 

 

 

CB5 protects the 24 volt ac output to

4

5

 

remote receptacle RC14, and 24 volt

 

 

 

output to field current regulator board

 

 

 

PC1 (CC/CV models only). If CB5

 

 

 

opens, weld output and 24 volt out-

 

 

 

put to RC14 stops. On units with op-

 

 

 

tional three−phase generator, gener-

 

 

 

ator power output at receptacle RC5

 

 

 

also stops if CB5 opens.

 

 

 

CB6 protects the 115 volt ac output

 

 

 

to remote receptacle RC14 (CC/CV

 

 

 

models only). If CB6 opens, 115 volt

 

 

 

output to RC14 stops.

 

 

 

CB10 protects the engine battery cir-

 

 

 

cuit. If CB10 opens, the engine will

 

 

 

not crank. CB10 automatically re-

 

 

 

sets when the fault is corrected.

 

 

 

CB11 protects the engine wiring har-

 

 

 

ness. On CC models, if CB11 opens

 

 

 

the max OCV circuit does not work

 

 

 

and open circuit voltage is variable at

 

 

 

all times (see max OCV note under

 

 

 

Weld Controls in Section 6-2). If

 

 

 

CB11 opens on CV models, weld

 

 

 

output stops (generator power is still

 

 

 

available).

 

 

 

CB12 protects the field flashing cir-

 

 

 

cuit. If CB12 opens, the generator

 

 

 

may not excite at start-up and weld

 

 

 

and generator power output may not

 

 

 

be available.

 

 

 

CB13 protects the engine shutdown

 

 

 

circuit. If CB13 opens, the engine

 

 

 

cranks but does not start.

 

 

 

Press button to reset breaker.

 

 

 

 

802 170-D / Ref. 802 311

OM-4406 Page 48

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Contents OM-4406 ProcessesDescription From Miller to You Table of Contents − Maintenance & Troubleshooting Directives StandardsDeccon111/02 Sound Level Information Deccon1sound11/02Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures ’AIR Comprimé peut provoquer des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiques− Definitions + − Starting InstructionsFalling equipment can cause Are possible hazards asCan cause severe burns. Do Serious injury and damageReturn To Table Of Contents Std Manufacturer’s Rating Labels For CE Products− 50 h Std CC Models CC/CV ModelsSymbols And Definitions − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models TIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Duty Cycle And Overheating12 kVA/kW Single-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 15 kVA/kW Three-Phase AC Output No Weld LoadVolt-Ampere Curve For CC/CV Models In AC TIG Mode Location Grounding − InstallationInstalling Welding Generator See Sections 5-2And Airflow ClearanceUsing Lifting Eye Mounting Surface Mounting Welding GeneratorSupporting The Unit To Bolt Unit In PlaceStop engine and let cool Installing Exhaust PipeTools Needed 1/2 Point exhaust pipe in desired diRead and follow all instruc Activating The Dry Charge Battery If ApplicableDo not overfill battery cells ChargerConnecting The Battery Reinstall cover after connecting batteryConnect Negative − Cable Last Coolant Recovery Tank Engine Prestart ChecksConnecting To Weld Output Terminals Selecting Weld Cable SizesConnecting To Remote 14 Receptacle RC14 On CC/CV Models Socket− Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionEngine Starting Controls Engine Indicator LightsDo not switch under load To Start Do not use etherExample Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label Set weld controls as shown toReturn To Table Of Contents − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionUse switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 ReceptacleEngine Oil Pressure Light Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control StickExample Combination Remote Amperage Control TIG At least once a month, run en − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles Open, contact Factory AuthoThree-Phase Power Connection Rear Of PanelClose panel opening if no connections are made to generator Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Circuit Breaker CB2 Circuit Breaker CB3 − Maintenance & Troubleshooting Maintenance LabelEvery 50 h Routine MaintenanceEvery 8 h Every 100 hEvery 2000 h ServiceEvery 1000 h Caterpillar Customer AssistanceTo clean air filter Servicing Air CleanerBy the warranty Do not clean housing with air hoseInspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. Reinstall cleanout plugTools Needed 3/8 Weld/Power Speed Adjustment Adjusting Engine SpeedIdle Speed Adjustment Engine Speed No LoadServicing Fuel And Lubrication Systems Overload Protection Diagnostic Checks While Running Diagnosing Causes Of Engine Fault ShutdownsPre-Start Diagnostic Checks Start Engine With No Load AppliedTroubleshooting Welding − CC ModelsWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV ModelsEngine Temperature is too high see Sections 5-7and Wiring harness and componentsShutdown switch is released Out Air in fuel system. See engine manual− Electrical Diagrams Circuit Diagram For CC Welding Generator215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-B − RUN-IN Procedure WetstackingWelding Generator Stop engine Do not touch hot exhaust Run-In Procedure Using Load BankProcedure at less than From flammables Do not PerformFrom flammables Run-In Procedure Using Resistance GridBank/grid Do not perform run-inSelecting Equipment − Generator Power GuidelinesHas this symbol Grounding Generator To Truck Or Trailer FrameEarth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated Electrical codesIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 117 116 103 102 115 FIG 114 105 104 101 120113 108 100 CC only 119 110 109 111 -4 or 51 52 85 FigDia Part Description Quantity Dia Part Description Quantity Mkgs 095 Control Box Assembly − CC Models Control Box Assembly − CC/CV Models Control Box Assembly − CC/CV Models -1Item Panel, Front w/Components − CC Models MS1 Panel, Front w/Components − CC/CV Models Panel, Front w/Components − CC/CV Models -1ItemPC6 192 PLG6 Hardware is common Not available unless listed 34 36 27 26Main Rectifier Assembly -1Item Main Rectifier Assembly Page Your distributor also gives SupportYour distributor and/or equipment manufacturer’s Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Transportation Department
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