Overload Protection | Miller Electric Big 40 CAT guide

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		7	Circuit Breaker CB11
	7		8	Circuit Breaker CB12
			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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Miller Electric Big 40 CAT manual Overload Protection

Contents

OM-4406 ProcessesDescription From Miller to You Table of Contents − Maintenance & Troubleshooting Directives StandardsDeccon111/02 Sound Level Information Deccon1sound11/02 Symbol Usage Arc Welding Hazards Engine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interference UN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereux DES 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’ouïe LA Chaleur DU Moteur peut pro- voquer un incendie ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures ’AIR Comprimé peut provoquer des blessures Principales normes de sécurité Information sur les champs électromagnétiques − Definitions + − Starting Instructions Falling equipment can cause Are possible hazards asCan cause severe burns. Do Serious injury and damage Return To Table Of Contents Std Manufacturer’s Rating Labels For CE Products− 50 h Std CC Models CC/CV Models Symbols 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 Models Fuel Consumption Duty Cycle And Overheating 12 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 Load Volt-Ampere Curve For CC/CV Models In AC TIG Mode Location Grounding − InstallationInstalling Welding Generator See Sections 5-2And Airflow Clearance Using Lifting Eye Mounting Surface Mounting Welding GeneratorSupporting The Unit To Bolt Unit In Place Stop engine and let cool Installing Exhaust PipeTools Needed 1/2 Point exhaust pipe in desired di Read and follow all instruc Activating The Dry Charge Battery If ApplicableDo not overfill battery cells Charger Connecting The Battery Reinstall cover after connecting batteryConnect Negative − Cable Last Coolant Recovery Tank Engine Prestart Checks Connecting To Weld Output Terminals Selecting Weld Cable Sizes Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket − Operating Welding Generator − CC Models Front Panel Controls For CC Models See Section Engine Starting Controls Engine Indicator LightsDo not switch under load To Start Do not use ether Example Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label Set weld controls as shown to Return To Table Of Contents − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See Section Use 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 Settings Remote 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 Autho Three-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 Label Every 50 h Routine MaintenanceEvery 8 h Every 100 h Every 2000 h ServiceEvery 1000 h Caterpillar Customer Assistance To clean air filter Servicing Air CleanerBy the warranty Do not clean housing with air hose Inspecting 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 Load Servicing Fuel And Lubrication Systems Overload Protection Diagnostic Checks While Running Diagnosing Causes Of Engine Fault ShutdownsPre-Start Diagnostic Checks Start Engine With No Load Applied Troubleshooting Welding − CC Models Welding − 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 Generator 215 296-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 Perform From flammables Run-In Procedure Using Resistance GridBank/grid Do not perform run-in Selecting Equipment − Generator Power GuidelinesHas this symbol Grounding Generator To Truck Or Trailer Frame Earth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated Electrical codes Industrial 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 Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Single-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 = Starting Amperage Typical 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 Fig Dia 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 -1Item PC6 192 PLG6 Hardware is common Not available unless listed 34 36 27 26 Main Rectifier Assembly -1Item Main Rectifier Assembly Page Your distributor also gives Support Your distributor and/or equipment manufacturer’s Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Transportation Department