Miller Electric RHC-3GD25B Specifications

MillerfiApril1991FORM:OM-458MEffectiveWithSerialNo.KA895189MODEL:TRAILBLAZERfi44GOWNERSMANUALIMPORTANT:Readandunderstandtheentirecontentsofthismanual,w

SectionNo.PageNo.SECTION6EVALUATINGAUXILIARYPOWERREQUIREMENTS6-1.AuxiliaryPowerGenerators186-2.LoadEvaluation196-3.GeneratorCapability216-4.StandbyPo

SectionNo.PageNo.SECTION10TROUBLESHOOTING10-1.General4210-2.BoosterBatteryJumpStarting4210-3.OverloadProtection4210-4.CircuitBoardHandlingPrecautions

SECTION1SAFETYRULESFOROPERATIONOFARCWELDINGPOWERSOURCE1-1.INTRODUCTIONWelearnbyexperience.Learningsafetythroughpersonalexperience,likeachildtouchinga

atmospherescontainingevenminuteamountsoftrichloroethyleneorperchloroethylene.C.FireandExplosionPreventionCausesoffireandexplosionare:combustiblesreach

Prohibiteduse.Neveruseacylinderoritscontentsforotherthanitsintendeduse,NEVERasasupportorroller.Locateorsecurecylinderssotheycannotbeknockedover.Passag

1-3.ARCWELDINGComplywithprecautionsin1-1, 1-2,andthissection.ArcWelding,properlydone,isasafeprocess,butacarelessoperatorinvitestrouble.Theequipmentcar

electricallyHOTbystraycurrentmayshock,possiblyfatally.DoNOTGROUNDtoelectricalconduit,ortoapipecarryingANYgasorflammableliquidsuchasoilorfuel.Three-pha

6.ANSIStandardZ49.2,FIREPREVENTIONINTHEUSEOFCUTTINGANDWELDINGPROCESSESobtainablefromtheAmericanNationalStandardsInstitute,1430Broadway,NewYork,NY10018

SECTION3SPECIFICATIONSTable3-1.SpecificationsRatedOutputAt100%DutyCycleACAmperagelDCAmperageRangesRangesMax.Open-CircuitVoltage(OCV)Single-PhaseACAux

IIJLIMITEDWARRANTYEFFECTIVE:AUGUST6,1990LThiswarrantysupersedesallpreviousMILLERwarrantiesandisexclusivewithnootherguaranteesorwarrantiesexpressedo

3-1.VOLT-AMPERECURVES(Charts3-1And3-2)./~RATEDWELDOUTPUTThevolt-amperecurvesshowthevoltageandamperageoutputcapabilitiesoftheweldinggenerator.Curveso

3-2.DUTYCYCLE(Chart3-3)3-3.DESCRIPTIONThedutycycleisthepercentageofatenminuteperiodthataweldinggeneratorcanbeoperatedatagivenoutputwithoutoverheatinga

Theservicelifeandoperatingefficiencyofthisunitarereducedwhentheunitissubjectedtoextremelevelsofdust,dirt,moisture,corrosivevapors,andextremeheat.A.Lif

4-3.CONNECTINGTHEBATTERY(Figure4-2)Donotrefuelifengineishotorrunning.aWARNING:BATTERYACIDcanburneyes,skin,destroyclothing,anddamageothermaterial.Wea

4-5.LUBRICATIONTheengineisshippedwithitscrankcasefilledwithSAE20break-inoil.Iftheoillevelisnotuptothefullmarkonthedipstick,addoilaccordingtotherecomme

Hlgh~FrequencyAssembly(seeSection9-7)ElectrodeWeldOutputTerminalRemoteAmperageControlReceptacleRemoteContactorControlReceptacleShieldIngGasValveSB-086

Table4-1.WeldCableSizeWeldingAmperesTotalCable(Copper)LengthInWeldCircuitNotExceeding*100ft.OrLess(30m)150ft.(45m)1200ft.J(60m)250ft.1(70m)300ft.(90m)

ToconnecttheRemoteContactorControlswitchtotheRemotereceptacle,insertthe2-prongplugfromtheRemoteContactorControlswitchintothereceptacle,androtatetheplu

Chart5-1.ACPowerCurveFor120(AndOptional240)VoltsDuplexReceptacle(NoWeldLoadCondition)C.ConnectionsThe120andoptional240voltsacduplexreceptaclesareforus

6.Installthe240voltsacreceptacleinthefrontpan-5-5.7.5KVA/KWPOWERPLANT(Chart5-2Andel.7.Affixthe240V13AAClabeloverexisting120V26AACdesignationonthenamep

ERRATASHEETAfterthismanualwasprinted,refinementsinequipmentdesignoccurred.Thissheetlistsexceptionstodataappearinglaterinthismanual.AMENDMENTTOSECTION5

B.ConnectionProcedureaWARNING:ELECTRICSHOCKcankill.Donottouchliveelectricalparts.Keepjunctionboxcoverinplacewhileengineisrunning.Stopengine,anddisc

doesnotrequiregrounding.Ifthegeneratorismountedonavehicle,thevehicleandgeneratorframesmustbeconnected.Ifthegeneratorissupplyingapermanentinstallationo

Table6-1.PowerRequirements*INDUSTRIALMOTORSRATINGAPPROXIMATESTARTINGWATTSAPPROXIMATERUNNINGWATTSFARMEOUIPMENTAINGAPPROXIMATESTARTINGWATTSAPPROXIMATERU

Table6-2.Single-PhaseInductionMotorStartingKVA/HPRequirementsMotorStartCodeLetterKVA/HP06.3H7.1J8.0K9.0L10.0M11.2N12.5~P14.0Ifacodeletterisnotpresento

120/240Volt60HzThree-WireServiceIe120/240VoltSingle-PhaseThree-WireGeneratorOutputConnectionDiagram6-1.StandbyPowerEquipmentAndConnectionsLoadS-0405Ne

6-5.AUXILIARYPOWEREXTENSIONCORDcordsofadequateamperagecapacity,andusethefolSELECTION(Tables6-3And6-4)lowingTables6-3and6-4toselectconductorsizeaccordi

Table6-4.CordLengthsFor240VoltLoadsCurrentInAmperesLoadInWattsMaximumAllowableCordLengthInFeet(Meters)ForConductorSize(AWG)*46810121451200700(213)450(

7-2.AMPERERANGESSWITCH(Figure7-1)ss/DONOTSWITCHUNDERLOADTheAMPERERANGESswitchprovidesfivecoarseacanddcamperageranges.Therangeofeachswitchpositionisd

IMPORTANT:TheAMPERAGE&VOLTAGEADJUSTMENTcontrolmustberotatedtothe100(maximum)positionwheneverthe7.5kVA,/kWacpowerplantisused.TheAMPERAGE&VOLTAG

A.STARTPosition7-10.CHOKE CONTROL(Figure7-1)!STARTHighfrequencyispresentfromthetimethecontactoriscloseduntilanarcisestablished.Onceanarcisestablished,

-IREMOTEC~TAOLI~TIONALIL.IT0 0 0 0?7J49 42p9SOLEMIDDSPVALVEL_J12VD.T~ATTERVTA0.~TEP(~TI~AL.)Diagram11-1.CircuitDiagramForWeldingGeneratorDIDL-I-JOM-4

ThisswitchisprotectedbyfuseFlocatedonthebottomoftheswitchassemblydirectlybehindthefrontpanel.Shouldthisfuseopen,theenginewillnotstart.SeeSection10-3fo

7-18.TACHOMETER(Optional)7-20.TEMPERATUREGAUGE(Optional)TheTemperaturegaugeregistersthecoolanttempera-Thetachometer,locatedontheradiatorenclosure,reg-

3.Selectandobtainproperelectrode(seeTable8-2.GASTUNGSTENARCWELDING(GTAW)9-3).WITHLOWCURRENTCONTROLOPTION4.PreparetungstenelectrodeaccordingtoSectionWA

15.RotatePOSTFLOWTIMERtodesiredpostflow12.PlaceAUTOIDLEswitchinthedesiredpositionaing.aposition.16.StarttheengineasinstructedinSection8-5.17.Connectde

3.PlacetheAUTOIDLEswitchintheONposition.PressureAndHighCoolantTemperatureShut-ThisshouldbedonetopermittheenginetowarmdownSystemswitch.upatidlerpm.8.Al

Table9-1.MaintenanceScheduleFrequency*MaintenanceEveryday.Checkfuel,oil,andcoolantlevels(seeSections4-4and4-5,andengineOwnersManual,F-163engine).Ever

Table9-2.AirCleanerServiceS-009114-89FollowTheseEasySteps:1.Stopengine.5.Wipeoutelementchamber7.Reinstallelement.withclean,dampcloth.2.Wipeoffcoverbef

9-3.BATTERYREPLACEMENTPROCEDURE(Figure9-1)WARNING:SPARKSORFLAMEScancauseBATTERYGASEStoEXPLODE;BATTERYACIDcanburneyesandskin.Stopenginebeforedisconnec

c.Ifacorrectedspecificgravityreadingof1.225at80F(27C)isnotobtained,replacetheventcapsandrechargethebatteryfollowingthebatterychargermanufacturersin

Table9-3.TungstenSizeElectrodeDiameterAmperageRange-Polarity-GasTypePureTungsten(GreenBand)DC-ArgonElectrodeNegative/StraightPolarityDC-ArgonElectrode

UTPAL~~JCASPE~JIPEDBYNATI~AALA~CLDCALELEcTPrCC~S5,5tS~5051lEStSjPACPOWERrLOWDPRENTIL5ELECTW~3th1FROAT VIEWAC2-DCPEVEPSE3-DCSTPAI~4TCircuitDiagramNo.

9-6.SERVICINGTHESPARKARRESTORMOVINGPARTScancauseseriousinjury.aWARNING:ENGINEEXHAUSTSPARKScancausefire.Exhaustsparkarrestormustbeinstalledinaccordanc

9-8.CARBURETORAIRTEMPERATURESELECTOR(Figure9-5)aCAUTION:IMPROPERAIRSELECTORTUBEADJUSTMENTcandamageengine.Usepropercarburetorairtemperatureselectorpos

OPTIONALFigure9-6.IdleControl/GovernorLinkageAdjustment3.Pullthearmtowardthefrontoftheweldinggeneratortotheidleposition.Maintainpressureonthearmtobut

IMPORTANT:Whenevergovernorsensitivityisadjusted,governorspeed(weldspeed)mustbereadjusted(seeSection9-9A).Wheneverthegovernorspeed(weldspeed)isadjusted

SECTION10TROUBLESHOOTING10-1.GENERALItisassumedthatproperinstallationhasbeenmade,accordingtoSection4ofthismanual,theoperatorisfamiliarwiththefunction

A.ResettingOverloadBreakers(Figure7-1)aWARNING:ReadandfollowsafetyinformationatbeginningofentireSection10-3beforeproceeding.Theoverloadbreakersareauto

10-5.TROUBLESHOOTING(Tables10-1,10-2,And10-3)4~WARNING:ELECTRICSHOCKcankill._____Donottouchliveelectricalparts.Stopengine,anddisconnectnegative()b

Table10-1.Weld/PowerTroubleshooting(Continued)WELDINGTROUBLEPROBABLECAUSEREMEDYNoweldor3kVA/kWauxiliarypoweroutput.Poorcontactbetweenbrushesandsliprin

Table10-2.AuxiliaryPowerTroubleshootingAUXILIARYPOWERPROBABLECAUSEREMEDYNo3kVA/kWpoweroutput;weldoutputavailable.OVERLOADBREAKERCB1orCB2open.ResetCB1o

Table10-3.EngineTroubleshootingENGINETROUBLEPROBABLECAUSEREMEDYEnginedc~snotcrank.IGNITIONswitchS7.CheckS7,andreplaceifnecessary.StartswitchPB1.Check

SECTION11ELECTRICALDIAGRAMSTACHOIETER(OPTI~AL)Diagram11-1.CircuitDiagramForWeldingGeneratorrr-i2~OVOLTRECEPTACLEKIT(~TID~1AL)I~TEI3<IBL~1~ff:iSCI-

hELDNEUTRALGROU~CASRE~JIREDBYNATIONALAICL~ALELECTRICC~ESso57 545~dQ4//45454J7s4~--.3~IFRONTVIEWI-AC2-XREVERSE3-XSTRAIGHTCircuitDiagramNo.SD-i36407-AOM

DIODEISOLATEDDRESETPOSITIVEBOUTPUT(DELAYOFF)RESET~BURDENRESISTORCircuitDiagramNo.SA-084076-ACEFHCTNEGATIVEUCircuitDiagramNo.SA-071600-ADiagram11-2.Cir

SECTION12CERTIFICATIONFORHIGHFREQUENCYARCWELDINGEQUIPMENT12-1.GENERALThefollowinginformationisnecessarytomakeaproperinstallationofthehigh-frequencyar

L.HighFrequency12-4.LOCATIONHighfrequencyisradiofrequencyenergy,eithercontinuousorpulsed,usedtostartorstabilizeaweldingarc.M.High-FrequencyAssistedArc

C.Grounding(Earthing)TheWeldCablesD.MetalBuildingsHowever,whenthehigh-frequencypowersourceisinstalledwithinametalbuilding,precautionsmustbetakentobesu

S-0021Figure12-5.InstallationOfHigh-FrequencyStabilizedArcWeldingPowerSource12-6.GUIDELINESFORINSTALLATIONOFHIGH-FREQUENCYASSISTEDARCWELDINGPOWERSOURC

SECTION13PARTSLISTOM-458Page55

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37Fig13-8SD-088637-E26324180.7943784476755756555460616248646566676863525150697053347149OM-458Page57

CERTIFICATENAMEOFEQUIPMENT:_____________________________MODELNO.SERIALNO._________________________DATE:_________________Thisequipmenthasbeentype-teste

ItemDia.PartNo.Mkgs.No.DescriptionQuantityFigure13-1.MainAssembly1089 517STRAP,fueltank22134771PLUG,protective.640sq(usedasenginedoorbumpersalso)63030

DescriptionQuantityFigure13-1.MainAssembly(Continued)ItemDia.No.Mkgs.PartNo.1611216I1I1111111122115051525354555657585960616263646566676869707172737475

ItemDia.PartNo.Mkgs.No.DescriptionQuantityFigure13-1.MainAssembly(Continued)101+113038DOOR,accessfrontlower1102134792LABEL,warninggeneralprecautionary

Figure13-2.Panel,FrontLowerw/Components(Fig13-1Item103)Figure13-2.Panel,FrontLowerw/ComponentsOPTIONALBESURETOPROVIDEMODELANDSERIALNUMBERWHENORDERING

234567891011121314151617181920212223108321Figure13-3.HFPanel(Fig13-2Item4)020623G*020603020 622095621601835010886016601038 887602042T2033373601838Ti07

1CR3034856208453605971231237944CT20950425iT03862160805097PC20722558TD10007699CR205926710CR104458811Cl05329612PCi07160913072635R500708007263314SR603570

-DescriptionQuantityPCi071609Figure13-5.CircuitCard,Weld/IdleControl(Fig13-4Item12)C50,54035522CAPACITOR,polyefilm.047ufbOy2C5152045868CAPACITOR,elctl

PC2072255Figure13-6.CircuitCard,Output-CurrentDetector(Fig13-4Item7)C50-52031670CAPACITOR,cerdisc.O5uf500VDC3C53,54000 859CAPACITOR,elctlt220uf35VDC2D

Figure13-7.Panel,Front-Upperw/ComponentsSD-086638-B5637r212289323130 29282720161917182625 24OM-458Page66

ItemDia.No.Mkgs.PartNo.1S120116222RiO0306863S40116104085 3635Si0845786Ri6059607S30443538CB1,21392669S2,701160910RC160417607369010041 329RC2~604103025

*Doesnotreflectactualpart.Figure13-8.GeneratorSD-086774-C12322614151716OM-458Page68

ItemDia.PartNo.Mkgs.No.DescriptionQuantityFigure13-8.Generator(Fig13-1Item71)1049650BRACKET,mtg-brushholder12018614BRUSHSET,(consistingof)13*044755BRU

DescriptionQuantityPartsForOptionalEquipment042 564047841047842137825602946041179010429020325041329042566TAC105738003648C20106632027 735010021042023F3

OPTIONSANDACCESSORIESRHC-3GD25B(#004735)Remotehandamperagecontrol.Furnishedwith20ft.(6m)cordandplug.RFC-23GD25A(#004737)Remotefootamperageandcontactor

OPTIONSANDACCESSORIESNO.3000-4FOUR-WHEELTANDEMTRAILER(#041015)Tandemaxledesignenablesthistrailertoridesmoothlyoverroughterrain.Theunitisequippedwithfe

OM.458M4/91RECEIVING-HANDLINGBeforeunpackingequipment,checkcartonforanydam-UsethefollowingspacestorecordtheModelDesignaagethatmayhaveoccurredduringsh