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Miller Electric Big 40 CAT 8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only),

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8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)

Ref. 197 399 / 802 332-E

Place Process/Contactor switch

in Electrode Hot - Stick position

when using three−phase genera-

tor (see Section 7-3).

Single-Phase Generator Power

1 120/240 V 50 A Receptacle

RC5

RC5 is connected to the optional

three−phase generator and supplies

60 Hz single-phase power at weld/

power speed. Maximum output from

RC5 is 12 kVA/kW. Power available

at RC5 is reduced when welding.

2 Circuit Breaker CB7

Circuit breaker CB7 protects single-

phase receptacle RC5 and the load

wires from overload. If CB7 opens, all

three−phase generator output stops

and the receptacle does not work.

Three-Phase Generator Power

Stop engine.

Power and weld outputs are

live at the same time. Discon-

nect or insulate unused

cables.

Have qualified person install ac-

cording to circuit diagram and

Generator Power Guidelines

(see Section 12).

Remove generator power panel

mounting screws. Tilt panel forward.

3 Lead 93

4 Lead 92

5 Lead 91

6 Lead 42 (Circuit Grounding

Lead)

7 Lead 90 (Neutral)

8 Isolated Neutral Terminal

9 Jumper Lead 42

10 Grounding Terminal

Jumper 42 is connected to lead 90 at

factory. Jumper 42 may be discon-

nected from neutral to meet applica-

ble electrical codes.

Lead 42 connects to front panel

Ground stud.

11 User-Supplied Leads

12 Circuit Breaker CB7 User

Terminals

Connect user-supplied leads to ter-

minals on CB7 and to the isolated

neutral terminal and grounding termi-

nal as necessary.

Circuit breaker CB7 protects

single-phase receptacle RC5

and the load wires from overload.

If CB7 opens, all three−phase

generator output stops and the

receptacle does not work.

Reinstall generator power panel.

Tools Needed:

Volts

Amps

KVA/KW

Single

120/240

50

12

Three

240

36

15

60 HzFrequency

Engine Speed 1850 RPM

AC Phase

1 Phase

3

Output

Lead 42 connects to GROUND stud on

front of unit.

Jumper 42 is connected to 90 at factory.

12

91 92 93

240V

120V

120V

240V

240V

1-Phase

3-Phase

3

4

5

6

7

8

9

10

11

12

Rear Of Panel

Three-Phase Power Connection

2

Single-Phase Power Connection

92

90

91

93

Close panel opening

if no connections are

made to generator.

Close panel

opening if no

connections

are made to

generator.

240V

Remove plug

before inserting

leads. Reinstall

bushing.

Contents

Main Big 40 CA T From Miller to You Page TABLE OF CONTENTS Declaration of Conformity for European Community (CE) Products Appleton, WI 54914 USA Declaration of Conformity for European Community (CE) Products Appleton, WI 54914 USA OM-4406 Page 1 Return To Table Of Contents SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING Warning: Protect yourself and others from injury read and follow these precautions. 1-1. Symbol Usage Marks a special safety message. 1-2. Arc Welding Hazards 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. FUEL can cause fire or explosion. MOVING PARTS can cause injury. OM-4406 Page 3 1-4. Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death. COMPRESSED AIR can cause injury. TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury. HOT METAL from air arc cutting and gouging can cause fire or explosion. 1-6. California Proposition 65 Warnings 1-7. Principal Safety Standards 1-8. EMF Information OM-4406 Page 5 Revenez la table des matires SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions. 2-1. Signification des symboles Identifie un message de scurit particulier. 2-2. Dangers relatifs au soudage larc 2-3. Dangers existant en relation avec le moteur LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou mme la mort. LACIDE DE LA BATTERIE peut pro- voquer des brlures dans les YEUX et sur la PEAU. OM-4406 Page 7 Revenez la table des matires LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. 2-4. Dangers lis lair comprim RESPIRER LAIR COMPRIM peut pro- voquer des blessures graves ou causer la mort. LAIR COMPRIM peut provoquer des blessures. LAIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo- quer des blessures. Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in- cendie ou une explosion. 2-6. Principales normes de scurit 2-7. Information sur les champs lectromagntiques SECTION 3 DEFINITIONS 3-1. Warning Label Definitions + Page Page + 2 3 4 1+ AAmperes VVolts Panel/Local Remote 3 n X Duty Cycle U0 SECTION 4 SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Output Range Rated Welding Welding Mode Weld Output 4-3. Volt-Ampere Curves For CC Models 4-4. Volt-Ampere Curves For CC/CV Models 4-5. Fuel Consumption 4-6. Duty Cycle And Overheating 4-7. AC Generator Power Curve 4-8. Optional Three-Phase Generator Curves 4-9. Volt-Ampere Curve For CC/CV Models In AC TIG Mode SECTION 5 INSTALLATION 5-1. Installing Welding Generator (See Sections 5-2 And 5-3) Page 5-3. Mounting Welding Generator Page 5-5. Activating The Dry Charge Battery (If Applicable) + Page 5-7. Engine Prestart Checks 5-8. Connecting To Weld Output Terminals 5-9. Selecting Weld Cable Sizes* 5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models SECTION 6 OPERATING WELDING GENERATOR CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) 6-3. Remote Amperage Control On CC Models (Optional) 6-4. Weld Control/Arc Condition Information Label Page SECTION 7 OPERATING WELDING GENERATOR CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 7-3. Process/Contactor Switch On CC/CV Models Process/Contactor Switch Settings 7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) SECTION 8 OPERATING AUXILIARY EQUIPMENT 8-1. 120 Volt And 240 Volt Receptacles 8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) 8-3. Optional Generator Power Receptacles Page 9-2. Routine Maintenance Every 8 h Every 50 h Every 100 h Every 250 h Every 1000 h Every 2000 h 9-3. Caterpillar Customer Assistance 9-4. Servicing Air Cleaner 9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler 9-6. Adjusting Engine Speed 9-7. Servicing Fuel And Lubrication Systems 9-8. Overload Protection 9-9. Diagnosing Causes Of Engine Fault Shutdowns 9-10. Troubleshooting A. Welding CC Models B. Welding CC/CV Models C. Standard Generator Power D. Optional Three-Phase Generator Power (CC/CV Models) E. Engine Page Page Page Page Page SECTION 11 RUN-IN PROCEDURE 11-1. Wetstacking 11-2. Run-In Procedure Using Load Bank 11-3. Run-In Procedure Using Resistance Grid + SECTION 12 GENERATOR POWER GUIDELINES 12-1. Selecting Equipment 12-2. Grounding Generator To Truck Or Trailer Frame 12-3. Grounding When Supplying Building Systems 12-4. How Much Power Does Equipment Require? 12-5. Approximate Power Requirements For Industrial Motors 12-6. Approximate Power Requirements For Farm/Home Equipment 12-7. Approximate Power Requirements For Contractor Equipment 12-8. Power Required To Start Motor 12-9. How Much Power Can Generator Supply? 12-10. Typical Connections To Supply Standby Power Pros weld and cut safely. Read the safety rules at the beginning of this manual. 12-11. Selecting Extension Cord (Use Shortest Cord Possible) SECTION 13 PARTS LIST Figure 13-1. Main Assembly Page Page Page Page Page Page Page Page Page Page Page Page Page Page Figure 13-7. Main Rectifier Assembly Page Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Effective January 1, 2003 (Equipment with a serial number preface of LC or newer) Please complete and retain with your personal records. For Service Always provide Model Name and Serial/Style Number. Owners Record