Run-In Procedure Using Load Bank | Miller Electric 400P, 500 X

11-2. Run-In Procedure Using Load Bank

		Stop engine.
		Do not touch hot exhaust pipe,
		engine parts, or load bank/grid.
	4	Keep exhaust and pipe away
		from flammables.
	2	NOTICE − Do not perform run-
		in procedure at less than 20
	1	volts weld output and do not
		exceed duty cycle or equip-
		ment damage may occur.
		1	Load Bank
		Turn all load bank switches Off. If
		needed, connect load bank to 115
		volts ac wall receptacle or genera-
		tor auxiliary power receptacle.
		2	Welding Generator
		Place A/V range switch in maxi-
		mum position, A/V control in mini-
		mum position, and Output Selector
		switch (if present) in either DC
		position.
		3	Weld Cables
		Connect load bank to generator
		weld output terminals using proper
		size weld cables with correct
		connectors. Observe correct
		polarity.
		Start engine and run for several
	3	minutes.
		Set load bank switches and then

		adjust generator A/V control so
		load equals rated voltage and
		current of generator (see name-
		plate, rating label, or the specifi-
		cations section in this manual).
		Check generator and load bank
		meters after first five minutes then
		every fifteen minutes to be sure
		generator is loaded properly.
		NOTICE − Check oil level frequent-
		ly during run-in; add oil if needed.
		It is recommended to run the weld-
		ing generator for two hours mini-
		mum and up to four hours under
		load. Place A/V control in minimum
		position, then turn off load bank to
		remove load. Run engine several
		minutes at no load.
			Stop engine and let cool.
		4	Engine Exhaust Pipe
		Repeat procedure if wetstacking
		is present.

S-0683

OM-4421 Page 59

Image 65

Miller Electric 400P, 500 X manual Run-In Procedure Using Load Bank, Keep exhaust and pipe away, From flammables

Contents

Processes OM-4421215 075QDescription File Engine Drive From Miller to You Table of Contents − Maintenance & Troubleshooting Decrot1/07 DirectivesStandards Decrotsound6/05 Manufacturer European Contact Notified Body Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burns Buildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosion Compressed Air Hazards Engine Hazards HOT Parts can cause burns and injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injury California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference − Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer Indique des instructions spécifiques LES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe DES Organes Mobiles peuvent pro voquer des blessures ’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures DES Organes Mobiles peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peut Principales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF En ce qui concerne les implants médicaux Std − Definitions− 50 h Std Manufacturer’s Rating Labels Some symbols are found only on export products Symbols And Definitions Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Volt-Ampere Curves For CC Models MIG Mode Stick ModeTIG Mode Volt-Ampere Curves For CC/CV Models 100% Duty Cycle At 400 Amperes Fuel ConsumptionDuty Cycle And Overheating Optional Three-Phase Generator Curves AC Generator Power Curve12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld Load Installing Welding Generator − InstallationLocation/Airflow Clearance Grounding1 Using Lifting Eye Mounting Welding Generator Stop engine and let cool Installing Exhaust Pipe Connecting The Battery Activating The Dry Charge Battery If Applicable Engine Prestart Checks Coolant Recovery Tank Stick and TIG Welding Connecting To Weld Output TerminalsMIG and Fcaw Welding Stop engine Selecting Weld Cable Sizes Connecting to Weld150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Socket Connecting To Remote 14 Receptacle RC14 On CC/CV Models OM-4421 Front Panel Controls For CC Models See Section − Operating Welding Generator − CC Models To Start Engine Starting ControlsEngine 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 Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV Models 14 AC/DC Voltmeter Optional Voltage/Amperage Adjust Switch And Remote 14 ReceptacleElectric shock can kill Process/Contactor Switch Settings Process/Contactor Switch On CC/CV Models Example Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models Optional Volt And 240 Volt Receptacles − Operating Auxiliary EquipmentAt 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 Label − Maintenance & Troubleshooting Routine Maintenance Checking Generator Brushes To clean air filter Servicing Air Cleaner Inspecting And Cleaning Optional Spark Arrestor Muffler Weld/Power Speed Adjustment Adjusting Engine SpeedEngine Speed No Load Standard Model Idle Speed Ad- justment To change oil and filter Servicing Fuel And Lubrication SystemsTo replace primary fuel filter While draining fuel tank Overload Protection Welding − CC Models Troubleshooting Welding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Only Standard Generator Power Engine Welding Symbols Circuit Diagram For CC Welding Generator − Electrical Diagrams 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 Specifications section in this Run-In Procedure Using Resistance GridJust generator A/V control so Manual Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Electrically Bond Generator How Much Power Does Equipment Require? Grounding When Supplying Building SystemsUse ground device as stated in electrical codes Amperes x Volts = Watts Approximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment How Much Power Can Generator Supply? Power Required To Start MotorSingle-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 -1Item Control Box Assembly − CC/CV Models TD1 214 3634 Panel, Front w/Components − CC Models Panel, Front w/Components − CC Models -1Item 40 39 Panel, Front w/Components − CC/CV Models Panel, Front w/Components − CC/CV Models -1Item 170 34 36 27 26 Hardware is common Not available unless listed 602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Wiring Harnesses PLG4 Harness, receptacle auxiliary power export models includesPage Support ServiceYour distributor also gives Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s