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Miller Electric 500D manual

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Table of contents for the manual

  • Page 1

    Processes Description TIG (GT A W) Welding Stick (SMAW ) Welding MIG (GMAW) Welding Engine Driven Welding Generator OM-4428 215 932K 2007 − 10 Visit our website at www.MillerWelds.com Flux Cored (FCA W ) Welding Air Carbon Arc (CAC-A) Cutting and Gouging File: Engine Drive Big Blue 500D B i g B l u e 6 0 0 X   (Deutz-Power ed)[...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your near est distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mill[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS SECTION 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 3[...]

  • Page 5

    OM-4428 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols or [...]

  • Page 6

    OM-4428 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous.  Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.  If ventilation is [...]

  • Page 7

    OM-4428 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can BLIND.  Always wear a face shield, rubber gloves, and protective clothing when working on a battery .  Stop engine before disconnecting or connect- ing battery cables or servicing battery .  Do not allow tools to cause sparks when working on a battery .  Do not use welder to cha[...]

  • Page 8

    OM-4428 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion.  Do not cut or gouge near flammables.  W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury .  Do not touch hot compressor or air system parts.  Let system cool down before touching or ser- vicing. READ INSTRUCTIONS.  [...]

  • Page 9

    OM-4428 Page 5 H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment.  Have only qualified persons familiar with electronic equipment perform this installation.  The user is responsible for having a qualified electrician promptly corre[...]

  • Page 10

    OM-4428 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des ble[...]

  • Page 11

    OM-4428 Page 7 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.  Ne pas toucher à mains nues les parties chau - des.  Prévoir une période de refroidissement avant d e travailler à l’équipement.  Ne pas toucher aux pièces chaudes, utiliser les outils recomman - dés et porter des gants de soudage et des vêtements épais [...]

  • Page 12

    OM-4428 Page 8 LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux.  Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance.  Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de sou- dage par points, de gougeage, du coupage[...]

  • Page 13

    OM-4428 Page 9 L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES.  Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore.  JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.  Uniquement utiliser à l’EXT[...]

  • Page 14

    OM-4428 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant d e démarrer ou d ’a rrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager l e moteur électrique à cause d’une tension et d’une fré - quence trop faibles.  N e pas[...]

  • Page 15

    OM-4428 Page 1 1 2-6. P r oposition californienne 65 A vertissem ents Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de[...]

  • Page 16

    OM-4428 Page 12 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions (For Wordless Labels) 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muf fler . 2 Read Owner ’s Manual. Read labels on unit. 3 Use Diesel Fuel only , and fill fuel tank. Leave room for expansion. 4 Warning! W atch O[...]

  • Page 17

    OM-4428 Page 13 3-2. Manufacturer ’ s Rating Labels CC Models CC/CV Models[...]

  • Page 18

    OM-4428 Page 14 3-3. Symbols And Definitions  Some symbols are found only on CE products. Stop Engine Fast (Run, W eld/ Power) Slow (Idle) Start Engine Starting Aid Battery (Engine) Engine Oil Pressure Engine Oil Check Injectors/ Pump Check V alve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/T rained Mechanic W elding Arc[...]

  • Page 19

    OM-4428 Page 15 SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And Engine Specifications W elding Mode W eld Output Range Rated W elding Output Maximum Open-Circuit V oltage Generator Power Rating Engine Fuel Capacity CC/DC 65 − 600 A (CC Models) 20 − 600 A (CC/CV Models) 600 A, 30 V olts DC, 40% Duty Cycle IFC Rating 500 A, 40 V olts DC, 95[...]

  • Page 20

    OM-4428 Page 16 4-3. V olt-Ampere Curves For CC Models 203 412 The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 DC AMPERES DC VOL TS Ranges 300 − Max 185 − [...]

  • Page 21

    OM-4428 Page 17 4-4. V olt-Ampere Curves For CC/CV Models 217 81 1 / 203 415 / 217 810 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. A. Stick Mode B. MIG Mode C. TIG Mode 0 20 40 60 80 100 0 100 200 300 400 500 60[...]

  • Page 22

    OM-4428 Page 18 4-5. Fuel Consumption The curve shows typical fuel use under weld or power loads. 193 093 0 50 100 150 200 250 300 350 400 450 500 DC WELD AMPERES A T 100% DUTY CYCLE 1800 RPM 0 IDLE Notes[...]

  • Page 23

    OM-4428 Page 19 Continuous Welding 4-6. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle ca n damage unit and void warranty . 100% Duty Cycle At 500 Amperes 202 356 4-7. AC Generator Power Curve 193 018 Th e ac power curve shows the gen- erator [...]

  • Page 24

    OM-4428 Page 20 4-8. Optional Three-Phase Generator Curves 197 472 / 197 473 Th e ac power curves show the gen- erator power available in amperes at the single-phase 120/240 volt re - ceptacle or three-phase 240 volt terminals. A. 12 kV A/kW Single-Phase AC Output (No Weld Load) B. 20 kV A/kW Three-Phase AC Output (No Weld Load) 180 190 200 210 220[...]

  • Page 25

    OM-4428 Page 21 SECTION 5 − INST ALLA TION install3 2007 − 04 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 ! Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes. ! Always ground generator frame to vehicle frame to pre- vent electric shock and static electrici[...]

  • Page 26

    OM-4428 Page 22 5-2. Using Lifting Eye Ref. 802 31 1 1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps in place. Lower lifting eye when not needed. T o lock the lifting eye in the upright position, insert a 3/8-16 x 1-1/2 in carriage bolt through slot in bracket a nd secure with nut (bolt and nut not supplied). T ools Needed: 2 1[...]

  • Page 27

    OM-4428 Page 23 5-3. Mounting Welding Generator T ools Needed: 9/16 in 2 2 4 W elding Unit In Place Bolting Unit In Place ! Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. NOTICE − Do not mount unit by supporting the base only at the four mounting brackets. [...]

  • Page 28

    OM-4428 Page 24 5-4. Installing Exhaust Pipe 1/2 in T ools Needed: Ref. 803 604 / Ref. 215 664 ! Stop engine and let cool.  Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. ether1 7/96 − 153 382-A / Ref. 215 664 ! Stop engine. ! Improper handling or expo- sure to ether can harm your health. Fo[...]

  • Page 29

    OM-4428 Page 25 5-6. Activating The Dry Charge Battery (If Applicable) ! Always wear a face shield, rubber gloves and protective clothing when working on a battery . Remove battery from unit. 1 V ent Caps 2 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 3 W ell Fill each cell with electrolyte to bottom of well (maximum). ! Do not overfill batte[...]

  • Page 30

    OM-4428 Page 26 5-8. Engine Prestart Checks  Check all engine fluids daily . Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. The Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.  This unit has a low oil pressure shut- down switch. However , some condi- t[...]

  • Page 31

    OM-4428 Page 27 5-9. Connecting T o Weld Output T erminals 803 602 / 803 778-A T ools Needed: 2 3/4 in 1 MIG and FC A W Welding For MIG and FCA W welding Direct Current Electrode Positive (DCEP) on CC/CV models, connect wire feeder cable to Positive (+) termi- nal on left and work cable to Negative ( − ) ter- minal on right. Use Process/Contactor[...]

  • Page 32

    OM-4428 Page 28 5-10. Selecting W eld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in W eld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals ! Stop engine before connecting to weld output terminals. ! Do not use worn, dam-[...]

  • Page 33

    OM-4428 Page 29 5-12. Connecting T o Remote 14 Receptacle RC14 On CC/CV Models Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by sup- plementary protector CB5. 24 VOL TS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG or Stick mode; 0 to +10 volts dc in TIG m[...]

  • Page 34

    OM-4428 Page 30 SECTION 6 − OPERA TING WELDING GENERA TOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 12 215 663 / 803 602 11 2 1 81 3 1 4 97 6 4 5 3 10[...]

  • Page 35

    OM-4428 Page 31 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1 ) Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). 2 Engine Control Switch Use switch to start and stop engine. T o Start : NOTICE − Do not use ether. Using et[...]

  • Page 36

    OM-4428 Page 32 6-3. Remote Amperage Control On CC Models (Optional) 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-1 1). Example: Combination Remote Amperage Control (Stick) Adjust Optional Remote Control Set Switches Set Range Set Control Ref. 154 862-A / Ref. 215 663 / 803 602 In Example: Range = [...]

  • Page 37

    OM-4428 Page 33 Notes W or k l i ke a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginni ng of this manual .[...]

  • Page 38

    OM-4428 Page 34 SECTION 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 215 664 / 802 602 2 1 91 4 1 5 10 7 6 4 5 11 8 13 OR 12 3[...]

  • Page 39

    OM-4428 Page 35 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1 ) Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). 2 Engine Control Switch Use switch to start engine, select engine speed ( if unit has auto idle option), an[...]

  • Page 40

    OM-4428 Page 36 7-3. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch ! W eld output terminals are ener- gized when Process/Contactor switch is in an Weld T erminals Always On position and the en- gine is running. ! DC voltage is still present at the weld terminals when Process/ Contactor switch is in the Re- mote On/Off Switch R[...]

  • Page 41

    OM-4428 Page 37 7-4. Remote V oltage/Amperage Control On CC/CV Models (Optional) 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-12 ). 0774 / Ref. 215 664 / Ref. 803 602 Example: Combination Remote Amperage Control (Stick) Adjust Optional Remote Control Set V/A Adjust Switch Set Range Control Not Used In Remote St[...]

  • Page 42

    OM-4428 Page 38 SECTION 8 − OPERA TING AUXILIAR Y EQUIPMENT 8-1. 120 V olt And 240 V olt Receptacles 191 624-A 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 30 A AC T wistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, GFCI Reset button pops out and receptacle does not work. C[...]

  • Page 43

    OM-4428 Page 39 8-2. Connecting T o Optional Three-Phase Generator (CC/CV Models Only) Ref. 197 399 / 802 332-B / 803 655  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[...]

  • Page 44

    OM-4428 Page 40 8-3. Optional Generator Power Receptacles (Standard Models) 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 16 A AC European Receptacle RC1 3 240 V 15 A AC Australian Receptacle RC1 4 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, the GFCI R[...]

  • Page 45

    OM-4428 Page 41 8-4. Generator Power Receptacles (Export Models)  Generator power is not affected by weld output. 1 130 V 32 A AC Receptacle RC1 2 220 V olt 16 A AC Receptacle RC2 3 130 V olt 16 A AC Receptacle RC3 Receptacles supply 60 Hz single-phase power at weld/power speed. 4 Supplementary Protector CB1 5 Supplementary Protectors CB2 And CB[...]

  • Page 46

    OM-4428 Page 42 SECTION 9 − MAINTENANCE (DEUTZ F4L201 1 − POWERED UNITS) 9-1. Maintenance Label (Deutz F4L201 1-Powered Units)[...]

  • Page 47

    OM-4428 Page 43 9-2. Routine Maintenance (Deutz F4L201 1-Powered Units) ! Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle engine fluids.  = Check  = Change  = Clean  = Replace * T o be do[...]

  • Page 48

    OM-4428 Page 44 9-3. Checking Generator Brushes Ref 215 158 ! Stop engine and let cool. 1 Generator Brush Mark and disconnect leads at brush hold- er cap. Remove brushes. Replace brushes if damaged or if brush material is at o r near minimum length. 1 Damaged Brushes New Length: 1-1/4 in (32 mm) Minimum Length: 5/8 in (16 mm) Replace Notes[...]

  • Page 49

    OM-4428 Page 45 9-4. Servicing Air Cleaner (Deutz F4L201 1-Powered Units) aircleaner1 9/00 − ST -153 929-B / ST-153 585 / Ref. S-0698-B ! Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty .  The air cleaner primary element can be[...]

  • Page 50

    OM-4428 Page 46 9-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L201 1-Powered Units) 803 656 / Ref. 215 664 ! Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover [...]

  • Page 51

    OM-4428 Page 47 9-6. Adjusting Engine Speed (Deutz F4L201 1-Powered Units) 803 657 ! Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine no load speed with a tachometer or fre- quency meter (see table for no load speeds). If necessary , adjust speed as follows: Start engine an[...]

  • Page 52

    OM-4428 Page 48 9-7. Servicing Fuel And Lubrication Systems (Deutz F4L201 1-Powered Units) 803 657 ! Stop engine and let cool. ! After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary , and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain V alve And Hose 3 Oil Fill Cap 4 Primary Fuel Filter (Fuel/Water S[...]

  • Page 53

    OM-4428 Page 49 9-8. Overload Protection (Deutz F4L201 1-Powered Units) Ref. 803 657 2 1 9 8 7 4 ! Stop engine.  When a supplementary protector , circuit breaker or fuse opens, it usu- ally indicates a more serious prob- lem exists. Contact Factory Autho- rized Service Agent. 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exciter winding from [...]

  • Page 54

    OM-4428 Page 50 SECTION 10 − MAINTENANCE (DEUTZ F3L912 − POWERED UNITS) 10-1. Maintenance Label (Deutz F3L912-Powered Units)[...]

  • Page 55

    OM-4428 Page 51 10-2. Routine Maintenance (Deutz F3L912-Powered Units) ! Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle engine fluids.  = Check  = Change  = Clean  = Replace * T o be don[...]

  • Page 56

    OM-4428 Page 52 10-3. Checking Generator Brushes Ref 215 158 ! Stop engine and let cool. 1 Generator Brush Mark and disconnect leads at brush hold- er cap. Remove brushes. Replace brushes if damaged or if brush material is at o r near minimum length. 1 Damaged Brushes New Length: 1-1/4 in (32 mm) Minimum Length: 5/8 in (16 mm) Replace Notes[...]

  • Page 57

    OM-4428 Page 53 10-4. Servicing Air Cleaner (Deutz F3L912-Powered Units) aircleaner1 9/00 − ST -153 929-B / ST-153 585 / Ref. S-0698-B ! Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty .  The air cleaner primary element can be [...]

  • Page 58

    OM-4428 Page 54 10-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units) 803 656 / Ref. 215 664 ! Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover e[...]

  • Page 59

    OM-4428 Page 55 10-6. Adjusting Engine Speed (Deutz F3L912-Powered Units) 803 658 / 134 730-C ! Stop engine. Engine speeds have been factory set and should not require adjust- ment. After tuning engine, check engine speeds with a tachometer . Se e table for proper no load speed. If necessary , adjust speed as fol- lows: 1 Speed Adjustment Screw 2 L[...]

  • Page 60

    OM-4428 Page 56 10-8. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) 803 658 ! Stop engine and let cool. ! After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary , and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain V alve And Hose 3 Oil Fill Cap 4 Primary Fuel Filter (Fuel/Water Se[...]

  • Page 61

    OM-4428 Page 57 10-9. Overload Protection (Deutz F3L912-Powered Units) Ref. 803 658 2 1 9 8 7 4 ! Stop engine.  When a supplementary protector , cir- cuit breaker or fuse opens, it usually in- dicates a mo re serious problem exists. Contact Factory Authorized Service Agent. 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exciter winding from ov[...]

  • Page 62

    OM-4428 Page 58 SECTION 1 1 − TROUBLESHOOTING 1 1-1. T roubleshooting A. Welding − CC Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Check position of Ampere Range switch. Check position of optional Polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and conn[...]

  • Page 63

    OM-4428 Page 59 B. Welding − CC/CV Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Weld T erminals Always On position, or place switch in a Remote On/Of f Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-12 and 7- 1[...]

  • Page 64

    OM-4428 Page 60 T rouble Remedy Low CV weld output. Set Ampere Range switch to highest range. Increase V oltage/Amperage Adjust Control setting. Min or max CV weld output only . Check position of V oltage/Amperage Adjust control and V oltage/Amperage Adjust switch. Repair or replace remote control device. Have Factory Authorized Service Agent check[...]

  • Page 65

    OM-4428 Page 61 E. Engine T rouble Remedy Engine will not crank. Check battery , and replace if necessary . Check battery connections and tighten if necessary . Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9- 8 or 10-9 ). Have Factory Authorized Service Agent check engine wiring harness and compon[...]

  • Page 66

    OM-4428 Page 62 SECTION 12 − ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For CC Welding Generator (Deutz F4L201 1-Powered Units)[...]

  • Page 67

    OM-4428 Page 63 215 221-E[...]

  • Page 68

    OM-4428 Page 64 Figure 12-2. Circuit Diagram For CC Welding Generator (Deutz F4L201 1-Powered Units) (Export Models)[...]

  • Page 69

    OM-4428 Page 65 235 275-A[...]

  • Page 70

    OM-4428 Page 66 Figure 12-3. Circuit Diagram For CC/CV Welding Generator (Deutz F4L201 1-Powered Units)[...]

  • Page 71

    OM-4428 Page 67 215 806-E[...]

  • Page 72

    OM-4428 Page 68 Figure 12-4. Circuit Diagram For CC/CV Welding Generator (Deutz F4L201 1-Powered Units) (Export Models)[...]

  • Page 73

    OM-4428 Page 69 235 276-A[...]

  • Page 74

    OM-4428 Page 70 Figure 12-5. Circuit Diagram For CC Welding Generator (Deutz F3L912-Powered Units)[...]

  • Page 75

    OM-4428 Page 71 215 807-D[...]

  • Page 76

    OM-4428 Page 72 Figure 12-6. Circuit Diagram For CC/CV Welding Generator (Deutz F3L912-Powered Units)[...]

  • Page 77

    OM-4428 Page 73 215 808-D[...]

  • Page 78

    OM-4428 Page 74 SECTION 13 − RUN-IN PROCEDURE run_in1 2007 − 04 13-1. W etstacking 1 W elding Generator Ru n diesel engines near rated volt- ag e and current during run-in period to properly seat piston rings and prevent wetstacking. See name- plate, rating label, or specifications section in this manual to find rated voltage and current. NOTIC[...]

  • Page 79

    OM-4428 Page 75 13-2. Run-In Procedure Using Load Bank S-0683 1 Load Bank T urn all load bank switches Of f. If needed, connect load bank to 1 15 volts ac wall receptacle or genera- tor auxiliary power receptacle. 2 Welding Generator Place A/V range switch in maxi- mum position, A/V control in mini- mum position, and Output Selector switch (if pres[...]

  • Page 80

    OM-4428 Page 76 13-3. Run-In Procedure Using Resistance Grid S-0684 1 Resistance Grid Use grid sized for generator rated output. Turn O f f grid. 2 Welding Generator Place A/V range switch in maxi- mum position, A/V control in mini- mum position, and Output Selector switch (if present) in either DC position. 3 Weld Cables Connect grid to generator [...]

  • Page 81

    OM-4428 Page 77 SECTION 14 − GENERA TOR POWER GUIDELINES  The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 14-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Pro[...]

  • Page 82

    OM-4428 Page 78 14-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device  Us e ground device as stated in electrical codes. ! Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.[...]

  • Page 83

    OM-4428 Page 79 14-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 285[...]

  • Page 84

    OM-4428 Page 80 14-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in [...]

  • Page 85

    OM-4428 Page 81 14-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not li[...]

  • Page 86

    OM-4428 Page 82 14-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices. ! Properly install and ground this e[...]

  • Page 87

    OM-4428 Page 83 14-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 840 4[...]

  • Page 88

    OM-4428 Page 84 SECTION 15 − P ARTS LIST  Hardware is common and not available unless listed.  A Deutz F4L201 1 engine-pow- ered unit is shown below . See insert for parts specific to a Deutz F3L912-powered unit. Parts not related to the engines are the same in both units. CC CC Models Only CV CC/CV Models Only 107 95 (CC ONL Y) 100 (Fig. 1[...]

  • Page 89

    OM-4428 Page 85 803 659 / 803 665 Deutz F3L912 Engine  A Deutz F4L201 1 en- gine-powered unit is shown below . See in- sert for parts specific to a Deutz F3L912-pow- ered unit. Parts not re- lated to the engines are the same in both units. 50 53 88 90 89 84 81 82 83 85 86 87 35 (Fig. 15-6) 54 64 66 63 65 57 59 58 61 62 60 56 55 23 32 38 2 36 37 [...]

  • Page 90

    OM-4428 Page 86 Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly Quantity 1 189 824 P ANEL, gen LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 199 294 P ANEL, gen LH ss 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 91

    OM-4428 Page 87 Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Continued) Quantity ♦ 174 064 IDLE, solenoid assy 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦ 175 937 BRACKET , support solenoid 1 . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 92

    OM-4428 Page 88 Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Continued) Quantity 88 189 908 V AL VE, drain fuel 180deg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 181 572 BUSHING, tank fuel 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 93

    OM-4428 Page 89 803 660-C 2 1 11 19 6 3 7 14 22 13 16 12 5 15 9 20 18 17 8 4 21 23 24 10 25 26 Figure 15-2. Control Box Assembly − CC Models Description Part No. Dia. Mkgs. Item No. Figure 15-2. Control Box Assembly − CC Models (Figure 15-1 Item 98) Quantity 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 . . . . . . . . . . . . . . . . . [...]

  • Page 94

    OM-4428 Page 90 Description Part No. Dia. Mkgs. Item No. Figure 15-2. Control Box Assembly − CC Models (Continued) Quantity 215 013 HARNESS, unit weld control (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG3 158 465 CONN, rect univ 084 12p/s 3row plug cable lkg 1 . . . . . . . . . [...]

  • Page 95

    OM-4428 Page 91 803 661-C 23 1 2 3 11 16 21 18 20 17 14 13 15 5 9 10 8 4 7 6 12 19 22 25 24 Figure 15-3. Control Box Assembly − CC/CV Models Description Part No. Dia. Mkgs. Item No. Figure 15-3. Control Box Assembly − CC/CV Models (Figure 15-1 Item 98) Quantity 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 . . . . . . . . . . . . . . . .[...]

  • Page 96

    OM-4428 Page 92 Description Part No. Dia. Mkgs. Item No. Figure 15-3. Control Box Assembly − CC/CV Models (Continued) Quantity 23 CB1 1, 12, 13 139 266 SUPPLEMENTAR Y PROTECT OR, man reset 1p 15a 250vac 3 . . . . . . . . . . . . . . 24 CR9 090 104 RELA Y , encl 12vdc spst 30a/15vdc 5pin flange mtg 1 . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 97

    OM-4428 Page 93  Hardware is common and not available unless listed. 803 662 11 10 9 8 7 22 13 12 39 37 36 38 34 35 32 20 21 25 27 26 24 23 28 30 18 19 15 16 17 14 2 40 41 42 1 6 3 5 4 29 31 33 Figure 15-4. Panel, Front w/Components − CC Models Description Part No. Dia. Mkgs. Item No. Figure 15-4. Panel, Front w/Components − CC Models (Figur[...]

  • Page 98

    OM-4428 Page 94 Description Part No. Dia. Mkgs. Item No. Figure 15-4. Panel, Front w/Components − CC Models (Continued) Quantity 192 558 HARNESS, range (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC6 148 439 HOUSING, rect univ 084 4p/s 1 row rcpt 1 . . . . . . . .[...]

  • Page 99

    OM-4428 Page 95 Description Part No. Dia. Mkgs. Item No. Figure 15-4. Panel, Front w/Components − CC Models (Continued) Quantity 35 HM 210 424 METER, hour 12-24VDC 2.25dia 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 TEMP 217 084 GAUGE, coolant temp 0 − 300 deg f 1 . . . . . . . . . . . . [...]

  • Page 100

    OM-4428 Page 96  Hardware is common and not available unless listed. 803 663 11 54 53 52 51 46 47 49 2 56 55 57 58 1 7 6 8 10 9 3 5 4 12 13 45 48 50 42 44 39 40 41 38 37 36 35 43 34 31 14 30 27 29 28 33 19 24 20 25 26 22 23 21 17 16 15 18 32 Figure 15-5. Panel, Front w/Components − CC/CV Models Description Part No. Dia. Mkgs. Item No. Figure 1[...]

  • Page 101

    OM-4428 Page 97 Description Part No. Dia. Mkgs. Item No. Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued) Quantity 6 S6 193 234 SWITCH, rotary 6 position gold contacts (included in control box harness, . . . . . . . . . . . . . . see Figure 15-3) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 102

    OM-4428 Page 98 Description Part No. Dia. Mkgs. Item No. Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued) Quantity 36 PC4, PC5 189 744 CIRCUIT CARD ASSEMBL Y , filter hf 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 039 046 TERMINAL, pwr output black 1 . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 103

    OM-4428 Page 99 802 404-C  Hardware is common and not available unless listed. 5 6 8 9 22 27 28 29 30 31 7 24 25 10 26 34 33 32 1 2 4 3 23 17 18 11 13 14 12 15 19 20 21 16 Figure 15-6. Generator Description Part No. Dia. Mkgs. Item No. Figure 15-6. Generator (Figure 15-1 Item 35) Quantity 1 132 053 SCREW, 375-16 x 1.50hexhd pln gr 5pld 6 . . . .[...]

  • Page 104

    OM-4428 Page 100 Description Part No. Dia. Mkgs. Item No. Figure 15-6. Generator (Continued) Quantity 21 049 026 SCREW, M10 − 1.5x 25 Hex Hd − pln 8.8 Pln 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 191 579 COVER, starter hole Perkins/Continental 1 . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 105

    OM-4428 Page 101  Hardware is common and not available unless listed. 802 279-A 1 2 3 4 6 5 7 8 9 Figure 15-7. Main Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 15-7. Main Rectifier Assembly (Figure 15-1 Item 100) Quantity SR3 215 910 RECTIFIER, environmental (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 106

    [...]

  • Page 107

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe[...]

  • Page 108

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 9 20-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters −[...]