Installation, Installing Welding Generator | Miller Electric OM-494

SECTION 5 − INSTALLATION

NOTE

When facing the front panel, the Welder B controls and weld terminals are on the right and the Welder A controls and weld terminals are on the left.

5-1. Installing Welding Generator

Movement

YDo Not Lift Unit From End

OR

Airflow Clearance

18in

(460 mm)

		18 in
	18 in	(460 mm)
	18 in
	(460 mm)
	18 in	18 in
	18 in	(460 mm)
	(460 mm)	(460 mm)
	(460 mm)

Location

OR

Grounding			Y Always securely fasten welding
				generator onto transport vehicle
				or trailer and comply with all DOT
1	2			and other applicable codes.
GND/PE	2		Y	Always ground generator frame
GND/PE			Y	Always ground generator frame
				to vehicle frame to prevent elec-
				tric shock and static electricity
				hazards.
			Y If unit does not have GFCI recep-
				tacles, use GFCI-protected ex-
				tension cord.
Electrically bond generator frame to			1	Equipment Grounding Terminal
Electrically bond generator frame to				(On Front Panel)
vehicle frame by metal-to-metal				(On Front Panel)
vehicle frame by metal-to-metal			2	Grounding Cable (Not Supplied)
contact.		3	2	Grounding Cable (Not Supplied)
contact.		3	3	Metal Vehicle Frame
			3	Metal Vehicle Frame
Y Bed liners, shipping skids, and some running			Connect cable from equipment ground
Y Bed liners, shipping skids, and some running			terminal to metal vehicle frame. Use #10
gears insulate the welding generator from the			terminal to metal vehicle frame. Use #10
gears insulate the welding generator from the			AWG or larger insulated copper wire.
vehicle frame. Always connect a ground wire			AWG or larger insulated copper wire.
vehicle frame. Always connect a ground wire				Be sure equipment connected to
from the generator equipment grounding termi-			Y	Be sure equipment connected to
nal to bare metal on the vehicle frame as shown.				the 240 V receptacles is GFCI-
				protected.

install1 11/02* − Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854

Notes

Work like a Pro!

Pros weld and cut safely. Read the safety rules at the beginning of this manual.

OM-494 Page 14

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Miller Electric OM-494 manual Installation, Installing Welding Generator

Contents

Visit our website at OM-494191 862P January ProcessesDescription Dual-Operator Engine Driven Welding Generator From Miller to You Table of Contents Options and Accessories Warranty 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 Symbols And Definitions − Definitions Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Description AC Generator Power Fuel Consumption Overheating Exceeding duty cycle can damage unit and void warrantyDuty Cycle And Overheating Reduce Duty Cycle Minutes CV/DC Mode CC/DC − Single ModeCC/DC − Dual Mode Volt-Ampere Curves − Installation Installing Welding Generator Read and follow all instruc Activating The Dry Charge BatteryDo not overfill battery cells Charger Connect − Cable Last Connecting The BatteryInstalling Exhaust Pipe Top View Tools Needed 1/2 Engine Prestart Checks Fuel Do not use gasoline. Gaso Line will damage engineOil Unexpected Weld Output can cause injury or fire Safety Information For Connecting To Weld Output TerminalsWeld Output Terminals Welder a Left Side Welder B Right Side Welder a Left Side Do not exceed machine duty cycle Stop engine Do not exceed machine duty cycle Connect electrode holder cables to Elec- trode receptacles When switch is in Straight position Place optional Polarity switches in ReVerse position when using CV weld re Switches are set correctly. See Section Connect wire feeder cables to Negative − terminals Connect wire feeder cables to CV recep- tacles Be sure Process Selector switches are Place optional Polarity switch in Re Making Single Operator CC Weld Connections 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Selecting Weld Cable Sizes150 ft 200 ft 250 ft Put terminals Remote 14 Receptacle Information Installing Ether Cylinder Optional Ether Starting AidAfter installing cylinder, wait at Socket Information Remote 14 Receptacle Connections Dual Operator Operation See -3for weld control descriptions − Operating the Welding GeneratorEngine Controls If light goes on, stop engine and check engine belt Weld Controls See Section Weld Control Descriptions See Section Do not switch under load or with out- put onDo not switch under load CV weld output for MIG is only available − Maintenance & Troubleshooting − Operating Auxiliary Equipment Every 250 h Every 100 hEvery 200 h Every 500 h Maintenance Label To clean air filter Servicing Air CleanerBy the warranty Do not clean housing with air hose Servicing Fuel And Lubrication Systems Servicing Optional Ether Starting Aid Adjusting Engine SpeedWeld/Power 1850 Cylinder Max Tools Needed 11/16 To adjust belt tensionChecking And Replacing Alternator Belt Stop engine To check belt tension Resetting Fan Belt Safety Shutdown Inspecting And Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools Needed 3/8 Circuit Protection Thermostats TP3 And TP4 Internal − Not Shown Troubleshooting Welding Repair or replace wire feeder Factory Authorized Service Agent check main rectifier SR2Factory Authorized Service Agent check main rectifier SR3 Formers T5 thru T10, and control board PC1 or PC5 Generator Power Engine OM-494 − Electrical Diagrams Circuit Diagram For Welding Generator 210 657-A − RUN-IN Procedure WetstackingMent damage may occur Check oil level frequently dur Run-In Procedure Using Load Bank4exceed duty cycle or equip- ment damage may occur Ing run-in add oil if needed Bank/grid Run-In Procedure Using Resistance GridProcedure at less than From flammables 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 311 103 96−SEE -2 101 25−SEE FIG 910 4748 57−SEE FIG 78−SEE FIG Item Dia Part Description Quantity Mkgs 189 Front Panel Front Panel -1Item Side Control Panels − Welder B Right Side Shown Side Control Panels -1Item Side Control Panels Generator Rectifier Assembly OM-494 Page Service Your distributor also givesSupport 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