Process/Contactor Switch | Miller Electric OM-4409 specs

6-3. Process/Contactor Switch

1

Process/Contactor Switch

!

Weld output terminals are ener-

gized when Process/Contactor

switch is in a Weld Terminals Al-

ways On position and the en-

gine is running.

!

DC voltage is still present at the

1

weld terminals when Process/

Contactor switch is in the Re-

mote On/Off Switch Required −

Stick position and the engine is

running.

Use switch to select weld process and

weld output on/off control (see table be-

low and Section 6-4).

Place switch in Remote On/Off Switch

Required positions to turn weld output

on and off with a device connected to

the remote 14 receptacle.

Place switch in Weld Terminals Always

On positions for weld output to be on

whenever the engine is running.

Use Stick position for air carbon arc

(CAC-A) cutting and gouging.

When switch is in a Stick position, the

arc drive (dig) circuit provides addition-

al amperage during low voltage (short

arc length conditions) to prevent “stick-

ing” electrodes.

The arc drive (dig) circuit is disabled

when switch is in MIG or TIG positions.

. The engine auto idle option does

not work in the Remote On/Off

Switch Required-TIG mode.

217 356-A

Process/Contactor Switch Settings

Switch Setting

Process

Output On/Off Control

Engine Auto Idle (Optional)

Remote On/Off Switch Re-

GTAW With HF Unit, Pulsing

quired − TIG, HF Required

At Remote 14 Receptacle

Not Active

Device, Or Remote Control

Or Scratch Start TIG

Remote On/Off Switch

Stick (SMAW) With Remote On/Off

At Remote 14 Receptacle

Active

Required − Stick

Remote On/Off Switch

Required − CV Feeder

MIG (GMAW)

At Remote 14 Receptacle

Active

Using Remote

Weld Terminals Always On −

MIG (GMAW)

Electrode Hot

Active

Wire

Weld Terminals Always On −

Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting

Electrode Hot

Active

Stick

And Gouging

Weld Terminals Always On −

TIG Scratch Start (GTAW)

Electrode Hot

Active

TIG, Scratch Start

OM-4409 Page 34

Image 38

Miller Electric OM-4409 manual Process/Contactor Switch Settings

OM-4409 specifications

The Miller Electric OM-4409 is a remarkable welding machine designed for both professional welders and enthusiastic hobbyists. Known for its reliability and efficiency, the OM-4409 stands out in the industrial landscape due to its advanced features and innovative technologies.

One of the main features of the OM-4409 is its impressive power output. With a rated output of 400 amps, it is capable of tackling a variety of welding applications, including MIG, TIG, and stick welding. This versatility allows users to switch between welding processes depending on the project requirements while ensuring consistent quality and performance.

The machine incorporates advanced inverter technology, which enhances its overall efficiency. Inverter technology allows for a compact design without sacrificing performance. The OM-4409 weighs significantly less than traditional transformer-based machines, making it more portable and easier to transport. Additionally, the inverter technology ensures that energy consumption is kept to a minimum, reducing operational costs.

Another notable characteristic of the Miller Electric OM-4409 is its user-friendly interface. The intuitive control panel provides easy access to settings and adjustments, allowing welders to fine-tune the machine to their specific needs. The digital display shows crucial parameters such as voltage, amperage, and wire feed speed, enabling welders to monitor their progress in real-time effectively.

Safety is paramount in industrial applications, and the OM-4409 does not disappoint. It is equipped with advanced safety features, including thermal overload protection and fault indication systems. These features ensure that the machine operates within safe limits, protecting both the user and the equipment.

The OM-4409 also boasts a robust build quality, designed to withstand the rigors of daily use in demanding environments. Its durable construction ensures longevity, minimizing maintenance and downtime.

In summary, the Miller Electric OM-4409 welding machine is a powerhouse that combines power, efficiency, and user-friendliness. With its inverter technology, versatility across various welding processes, advanced safety features, and robust design, it represents an excellent investment for any welding professional looking to enhance their capabilities. Whether for heavy-duty industrial applications or intricate metalwork, the OM-4409 delivers unmatched performance and reliability.

Contents

Description OM-4409206Processes File Engine Drive From Miller to You Table of Contents Troubleshooting Tables − Operating Optional Battery Charger− Troubleshooting − Parts List Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burns ARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosion Engine Hazards Compressed Air Hazards Fire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injury 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 Indique des instructions spécifiques LE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux 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 LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures ’EMPLOI Excessif peut Information EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité En ce qui concerne les implants médicaux Symbols And Definitions − Definitions Air Compressor Specifications − SpecificationsWeld, Power, And Engine Specifications Sound Level Table Lifting Eye Weight Rating Dimensions, Weights, And Operating AnglesWeight MIG Mode DC Stick ModeAC Stick Mode Optional Stick And MIG Volt-Ampere Curves TIG Volt-Ampere Curves DC TIG ModeAC TIG Mode Optional 100% Duty Cycle At 500 Amperes Fuel ConsumptionDuty Cycle And Overheating 40% Duty Cycle At 600 Amperes Generator AC Power Curve 20 kVA/kW Three-Phase AC Output No Weld Load Optional 3-Phase Generator Power Curves12 kVA/kW Single-Phase AC Output No Weld Load Optional Battery Charging Output Curve Air Compressor Output Curve Manufacturing Rating Label Location/Airflow Clearance − InstallationInstalling Welding Generator Grounding1 Mounting Surface Mounting Welding GeneratorSupporting The Unit To Bolt Unit In Place Stop engine and let cool Installing Optional Spark Arrestor MufflerMount the muffler with the clean- out plug to the outside Be sure to tighten rain cap mounting screw Do not overfill battery cells Activating The Dry Charge Battery If ApplicableConnecting The Battery Reinstall cover after connecting battery Stop engine Using The Optional Battery Disconnect SwitchSwitch may be locked using a customer-supplied padlock Engine/Compressor Prestart Checks MIG And Fcaw Welding Connecting To Weld Output TerminalsStick And TIG Welding 150 ft 200 ft 250 ft Connecting to weld Output terminalsSelecting Weld Cable Sizes Connecting To Remote 14 Receptacle RC14 Socket Connecting To The Air Compressor Open Position Closed Position − Operating the Welding Generator Controls See Section Description Of Controls See Section Process/Contactor Switch Process/Contactor Switch Settings Example Combination Remote Amperage Control TIG Using Remote Voltage/Amperage ControlExample Combination Remote Amperage Control Stick At least once a month, run en − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles Is working properly Connecting To Optional AC Power Plant Supplementary Protector CB2 Supplementary Protector CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 Determining Battery Charging Current − Operating Optional Battery ChargerBattery Charge Controls Output Selector Switch Battery Charge Cable Connections Battery Charging Procedure To control battery charging output using a Connect Remote Or Control Device Momentary-On Switch Jump Starting ProcedureCharge battery for 10 minutes before jump starting battery Cables − ENGINE/GENERATOR Maintenance Engine Maintenance Label Routine Engine/Generator Maintenance Material Thickness Reference Chart Checking Generator Brushes To clean air filter Servicing Engine Air CleanerAir cleaner primary element can Optional Keep nozzle 2 in 51 mm from element Inspecting/Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools Needed Adjusting Engine Speed Do not set engine speed higher than specified To change oil and filter Servicing Engine Fuel And Lubrication SystemsWipe up spilled fuel To drain water from fuel system Engine/Generator Overload Protection − AIR Compressor Maintenance Air Compressor Maintenance Label Routine Air Compressor Maintenance Remove engine air cleaner cover Servicing Compressor Air CleanerCompressor Air Cleaner Reinstall primary element and cover dust ejector down Compressor Overload Protection See -8for engine/genera- tor overload protection Engine oil drain and compressor oil Servicing Air CompressorTo change compressor oil and filter To replace air/oil separator Adjusting Compressor Air Pressure Welding − TroubleshootingTroubleshooting Tables Standard Generator Power Optional AC Power Plant Engine Optional Battery Charging Air Compressor − AIR Compressor Diagram Circuit Diagram For Air Compressor − Circuit Diagram Circuit Diagram For Welding Generator 221 915−C Welding Generator − RUN-IN ProcedureWetstacking Output and do not exceed duty Run-In Procedure Using Load BankFrom flammables Cycle or equipment damage may Run-In Procedure Using Resistance Grid − AIR Compressor Tables Flow Of Free Air CFM Through Orifices Of Various Diameters Sec 15 sec 21 sec Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Use ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = Watts 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 / Volts = Starting Amperage Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Amperage Range Gas Type Polarity Preparing Tungsten For DC Electrode Negative Dcen WeldingPreparing Tungsten For AC Welding − Guidelines for TIG Welding Gtaw Positioning The Torch Welding direction Form pool Tilt torch Torch Movement During WeldingTungsten Without Filler Rod Tungsten With Filler Rod Positioning Torch Tungsten For Various Weld Joints Butt Weld And Stringer Bead Joint Lap Joint Corner Joint 133 148 147 − Parts ListHardware is common and not available unless listed 126 121 109 120 122 108 102 103 105 106 107 7273 Dia Part Description Quantity Mkgs 224265 199505 CT1 21 22 C1/D1 CB11,CB12,CB13 Hardware is common Not available unless listed 2724 40 39 CB2 Fuel Generator Generator -1Item 172555 Main Rectifier Assembly Air Compressor Assembly 10 9 1516 8281 7371 Air Compressor Assembly -1Item Clutch Support ServiceYour distributor also gives For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s