Connecting To Weld Output Terminals | Miller Electric 400P, 500 X

5-8. Connecting To Weld Output Terminals

Stick and TIG Welding

For Stick and TIG welding Direct Current Elec- trode Positive (DCEP), connect electrode holder cable to Positive (+) terminal on left and work cable to Negative (−) terminal on right.

For Direct Current Electrode Negative (DCEN), reverse cable connections.

If equipped with optional Polarity switch or op- tional Polarity/AC switch, connect electrode holder cable to Electrode (+) terminal on left and work cable to Work (−) terminal on right.

MIG and FCAW Welding

For MIG and FCAW welding Direct Current Electrode Positive (DCEP) on CC/CV models, connect wire feeder cable to Positive (+) termi- nal on left and work cable to Negative (−) ter- minal on right. Use Process/Contactor switch to select type of weld output (see Section 7-3).

For Direct Current Electrode Negative (DCEN), reverse cable connections.

If equipped with optional Polarity switch or op- tional Polarity/AC switch, connect wire feeder cable to Electrode (+) terminal on left and work cable to Work (−) terminal on right.

! Stop engine.

1Positive (+) Weld Output Terminal

2Negative (−) Weld Output Terminal

!Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine.

3 Weld Output Terminal

4Supplied Weld Output Terminal Nut

5Weld Cable Terminal

6 Copper Bar

Remove supplied nut from weld output termi- nal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar. Do not place anything between weld cable termi- nal and copper bar. Make sure that the sur- faces of the weld cable terminal and cop- per bar are clean.

	1
Tools Needed:
3/4 in	2

6

3

Do not place

anything between weld cable terminal and copper bar.

4

5

Correct Installation

Incorrect Installation

803 602 / 803 778-A

OM-4421 Page 26

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Miller Electric 400P, 500 X Connecting To Weld Output Terminals, Stick and TIG Welding, MIG and Fcaw Welding, Stop engine

Contents

OM-4421215 075Q ProcessesDescription File Engine Drive From Miller to You Table of Contents − Maintenance & Troubleshooting Decrot1/07 DirectivesStandards Manufacturer European Contact Notified Body Decrotsound6/05 Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burns Fumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosion Engine Hazards Compressed Air Hazards Welding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injury Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interference Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiques DES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peu DES Organes Mobiles peuvent pro voquer des blessures Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peut Proposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicaux Std − Definitions− 50 h Std Manufacturer’s Rating Labels Symbols And Definitions Some symbols are found only on export products Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Volt-Ampere Curves For CC Models Stick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV Models 100% Duty Cycle At 400 Amperes Fuel ConsumptionDuty Cycle And Overheating AC Generator Power Curve Optional Three-Phase Generator Curves12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld Load − Installation Installing Welding GeneratorLocation/Airflow Clearance Grounding1 Using Lifting Eye Mounting Welding Generator Installing Exhaust Pipe Stop engine and let cool Activating The Dry Charge Battery If Applicable Connecting The Battery Coolant Recovery Tank Engine Prestart Checks Connecting To Weld Output Terminals Stick and TIG WeldingMIG and Fcaw Welding Stop engine Connecting to Weld Selecting Weld Cable Sizes150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket OM-4421 − Operating Welding Generator − CC Models Front Panel Controls For CC Models See Section Engine Starting Controls To StartEngine Gauges And Meters Weld Controls Example Combination Remote Amperage Control Stick Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label OM-4421 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See Section 14 AC/DC Voltmeter Optional Voltage/Amperage Adjust Switch And Remote 14 ReceptacleElectric shock can kill Process/Contactor Switch On CC/CV Models Process/Contactor Switch Settings Remote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIG − Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesAt least once a month, run en If a Supplementary Close panel opening if no connections are made to generator Three-Phase Power ConnectionRear Of Panel Supplementary Protector CB2 Supplementary Protector CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 − Maintenance & Troubleshooting Maintenance Label Routine Maintenance Checking Generator Brushes Servicing Air Cleaner To clean air filter Inspecting And Cleaning Optional Spark Arrestor Muffler Adjusting Engine Speed Weld/Power Speed AdjustmentEngine Speed No Load Standard Model Idle Speed Ad- justment Servicing Fuel And Lubrication Systems To change oil and filterTo replace primary fuel filter While draining fuel tank Overload Protection Troubleshooting Welding − CC Models Welding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models Only Engine Welding Symbols − Electrical Diagrams Circuit Diagram For CC Welding Generator 223 522-B Circuit Diagram For CC/CV Welding Generator 223 523-B Welding Generator − RUN-IN ProcedureWetstacking From flammables Run-In Procedure Using Load BankKeep exhaust and pipe away Run-In Procedure Using Resistance Grid Specifications section in thisJust generator A/V control so Manual − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Electrically Bond Generator Grounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated in electrical codes Amperes x Volts = Watts Approximate 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 Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Power Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting Amperage Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Parts List 128 93 −6 105 104 100 101 102 103 Main Assembly 010 Figures 13-2 Figures 13-4 Control Box Assembly − CC Models 087 Control Box Assembly − CC/CV Models Control Box Assembly − CC/CV Models -1Item TD1 214 Panel, Front w/Components − CC Models 3634 Panel, Front w/Components − CC Models -1Item Panel, Front w/Components − CC/CV Models 40 39 Panel, Front w/Components − CC/CV Models -1Item 170 Hardware is common Not available unless listed 34 36 27 26 602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Wiring Harnesses Harness, receptacle auxiliary power export models includes PLG4Page Support ServiceYour distributor also gives To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s