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Miller Electric OM-494 manual Making Single Operator CC Weld Connections

Models: OM-494

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5-14. Making Single Operator CC Weld Connections

Direct Current Electrode Positive (DCEP) connections are shown.

Welder A (left) Terminals Inactive

In Single Operator Mode

Welder B(Right) Side

Note position

of Process

Selector

switch.

1

3

2

Tools Needed:

	3/4 in			190 377 / 802 292-A
	3/4 in
	Y Stop engine.		Single Operator mode. (see Section	to Negative (−) terminal and electrode hold-
	Y Do not exceed machine duty cycle.		5-8).	er cable to CC terminal.
	Y Do not exceed machine duty cycle.	. See Section 5-15 for proper cable size.		For Stick/TIG Direct Current Electrode Neg-
	. Welder A (left) weld output terminals	. See Section 5-15 for proper cable size.		For Stick/TIG Direct Current Electrode Neg-
	. Welder A (left) weld output terminals	See Section 5-15for proper cable size.		ative (DCEN), connect work cable to CC
	are disabled in Single Operator mode.	See Section 5-15for proper cable size.		terminal and electrode holder cable to Neg-
	Connect only to Welder B (right) termi-	1	Strain Relief	ative (−) receptacle.
	nals for Single Operator mode opera-	Route cables through strain reliefs.		If unit has the Polarity switch option, con-
	tion.	2	Electrode Holder Cable	nect work cable to Work terminal and elec-
	. Use Single Operator mode for CC weld-	3	Work Cable	trode holder cable to Electrode receptacle.
	. Use Single Operator mode for CC weld-	3	Work Cable	. Be sure Process Selector switch is set
	ing only. Welder A and Welder B CV	For Stick/TIG welding Direct Current Elec-		. Be sure Process Selector switch is set
	weld output terminals are disabled in	trode Positive (DCEP), connect work cable		correctly. See Section 6-3.

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Miller Electric OM-494 manual Making Single Operator CC Weld Connections

Contents

Description ProcessesVisit our website at OM-494191 862P January Dual-Operator Engine Driven Welding GeneratorFrom Miller to You Table of Contents Options and Accessories Warranty Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards 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 LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions Symbols And DefinitionsWeld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles DescriptionFuel Consumption AC Generator PowerDuty Cycle And Overheating Exceeding duty cycle can damage unit and void warrantyOverheating Reduce Duty Cycle MinutesCC/DC − Dual Mode CC/DC − Single ModeCV/DC Mode Volt-Ampere CurvesInstalling Welding Generator − InstallationDo not overfill battery cells Activating The Dry Charge BatteryRead and follow all instruc ChargerInstalling Exhaust Pipe Connecting The BatteryConnect − Cable Last Top View Tools Needed 1/2Oil Engine Prestart ChecksFuel Do not use gasoline. Gaso Line will damage engine Weld Output Terminals Safety Information For Connecting To Weld Output TerminalsUnexpected Weld Output can cause injury or fire Welder a Left Side Welder B Right SideDo not exceed machine duty cycle Welder a Left SideConnect electrode holder cables to Elec- trode receptacles Stop engine Do not exceed machine duty cycleVerse position when using CV weld re Place optional Polarity switches in ReWhen switch is in Straight position Switches are set correctly. See SectionConnect wire feeder cables to CV recep- tacles Connect wire feeder cables to Negative − terminalsBe sure Process Selector switches are Place optional Polarity switch in Re Making Single Operator CC Weld Connections 150 ft 200 ft 250 ft Selecting Weld Cable Sizes350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Put terminalsAfter installing cylinder, wait at Installing Ether Cylinder Optional Ether Starting AidRemote 14 Receptacle Information Socket InformationDual Operator Operation Remote 14 Receptacle ConnectionsEngine Controls − Operating the Welding GeneratorSee -3for weld control descriptions If light goes on, stop engine and check engine beltWeld Controls See Section Do not switch under load Do not switch under load or with out- put onWeld Control Descriptions See Section CV weld output for MIG is only available− Operating Auxiliary Equipment − Maintenance & TroubleshootingEvery 200 h Every 100 hEvery 250 h Every 500 hMaintenance Label By the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hoseServicing Fuel And Lubrication Systems Weld/Power 1850 Adjusting Engine SpeedServicing Optional Ether Starting Aid CylinderChecking And Replacing Alternator Belt To adjust belt tensionMax Tools Needed 11/16 Stop engine To check belt tensionResetting Fan Belt Safety Shutdown Reinstall cleanout plug Tools Needed 3/8 Inspecting And Cleaning Optional Spark Arrestor MufflerThermostats TP3 And TP4 Internal − Not Shown Circuit ProtectionWelding TroubleshootingFactory Authorized Service Agent check main rectifier SR3 Factory Authorized Service Agent check main rectifier SR2Repair or replace wire feeder Formers T5 thru T10, and control board PC1 or PC5Engine Generator PowerOM-494 Circuit Diagram For Welding Generator − Electrical Diagrams210 657-A Ment damage may occur − RUN-IN ProcedureWetstacking 4exceed duty cycle or equip- ment damage may occur Run-In Procedure Using Load BankCheck oil level frequently dur Ing run-in add oil if neededProcedure at less than Run-In Procedure Using Resistance GridBank/grid From flammablesHas this symbol − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer FrameHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Use ground device as stated Electrical codesApproximate 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 WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible311 103 96−SEE -2 101 25−SEE FIG 910 − Parts List4748 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 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