Miller 819A Technical Manual Download Page 1

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Description

Belt-Driven Generator

TM-268 819A

2014−11

Eff. w/MD040275R And Following

4 kW And 7.5 kW

Belt-Drive Generators

Summary of Contents for 819A

Page 1: ...Visit our website at www MillerWelds com Description Belt Driven Generator TM 268 819A 2014 11 Eff w MD040275R And Following 4 kW And 7 5 kW Belt Drive Generators...

Page 2: ...4kW GENERATOR 10 7 1 Troubleshooting Table 10 7 2 Field Flashing 11 SECTION 8 TROUBLESHOOTING 7 5kW GENERATOR 12 8 1 Troubleshooting Table 12 8 2 Troubleshooting Circuit Diagram For Welding Generator...

Page 3: ...ccording to instructions in Troubleshooting Section before touching any parts MOVING PARTS can injure D Keep away from moving parts such as fans belts and rotors D Keep away from pinch points such as...

Page 4: ...stallation regularly checked and maintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of...

Page 5: ...cap 1 3 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer...

Page 6: ...l Safety Symbols And Definitions Moving parts can injure Safe100 2012 08 2 2 Miscellaneous Symbols And Definitions Circuit Breaker Read Operator s Manual A Amperes V Volts Positive Negative Alternatin...

Page 7: ...pe Output Generator Speed Belt Drive Pulley Single Phase 4 kVA kW 20 A 120 240 V 60 Hz or 115 230 V 50 Hz 1 0 Power Factor 100 Duty Cycle 3000 rpm 50 Hz 3600 rpm 60 Hz Generator Dimensions Control Box...

Page 8: ...res available from the generator 0 50 100 150 200 250 300 0 5 10 15 20 25 30 35 40 45 50 AC AMPERES AC VOLTS 0 50 100 150 200 250 300 0 5 10 15 20 25 30 35 40 AC AMPERES AC VOLTS 0 50 100 150 200 250...

Page 9: ...ide Of Generator During Heavy Service Clean Monthly Service 7 5 kW Generator Brushes And Slip Rings Service More Often In Dirty Conditions 7 5 kW Model Stop engine When a circuit breaker opens it usua...

Page 10: ...g generator output 5 Capacitor C1 Engine speed and capacitor value determinegenerator output 6 Generator Power Circuit Breaker CB1 Protects the generator windings from overload 7 Terminals 1T 2T 3T Pr...

Page 11: ...t to prevent ro tor failure from overheating 5 Control Board PC2 Works with PC1 to regulate revolv ing field current The PWM pulse width modulation signal originates on PC2 and is sent to PC1 6 Genera...

Page 12: ...e Section 4 2 Check connections at receptacle RC4 Be sure battery voltage is present 12 volts DC to enable control relay CR1 Check control relay CR1 Check all connections check coil continuity check f...

Page 13: ...1T 3 Terminal 2T 4 Battery Negative Lead 5 Battery Positive Lead 6 Circuit Breaker CB1 Be sure CB1 is ON Flash the field by connecting negat ive of battery to 2T With the genera tor running momentaril...

Page 14: ...Check slip rings wiring to brushes and brush position on slip rings Install new brushes if indicated See Section 8 8 Disconnect leads 12 and 13 from brushes and check continuity across slip rings nom...

Page 15: ...nections at platform generator and control box Verify generator is running at 3600 rpm 60 Hz or 3000 rpm 50 Hz If generator voltage is approximately 60 volts instead of normal 230 240 volts AC replace...

Page 16: ...ata Ridge denotes Pin 1 Ridge denotes Pin 1 PLG1 PLG31 Pin 5 Circuit Common I1 Pin 7 Circuit Common RC1 V13 V12 Voltage readings taken with PLG1 connected to RC1 on PC2 RC31 V11 V10 Voltage readings t...

Page 17: ...e single arrow reference to circuit common lead 42 double arrow reference to points indicated e Wiring Diagram see Section 10 V1 Thru V6 Taken At Basket Receptacle V1 X to Y 240 volts AC 10 V2 X to Z...

Page 18: ...5 ms 5 V B Pulse Width Modulation PWM Signal Between Power Board PC1 And Control Board PC2 V11 on Troubleshooting Circuit Diagram gnd gnd The waveforms represent the output of the generator When opera...

Page 19: ...RC31 7 unless noted Receptacle Pin Value RC31 1 Pulse Width Modulation PWM Signal 1 5 volts at no load voltage increases with generator load to approximately 4 3 volts DC at maximum 2 Shutdown Signal...

Page 20: ...e Feedback 240 volts AC with respect to RC1 1 3 Pulse Width Modulation PWM Signal 1 5 volts at no load voltage increases with generator load to approximately 4 3 volts DC at maximum 4 Shutdown Signal...

Page 21: ...lders Replace brushes if damaged or if brush is at or near minimum length Cleaning Slip Rings Visually inspect slip rings Under normal use rings turn dark brown If slip rings are corroded or surface i...

Page 22: ...ion Change switch position if unit is run at 50 Hz SW1 OFF 2 1 R68 3 2 7 6 8 5 4 1 R56 C20 R57 C21 D20 R41 C26 R55 D18 R47 R54 R53 U6 D26 R39 C14 R28 C19 S1 D25 C17 C13 C12 R30 C27 D13 D15 D30 R67 R59...

Page 23: ...tacle rating If output voltage is low or not pres ent at platform receptacles check voltages at generator terminal block TE1 see Section 8 2 If TE1 voltages are correct check wiring to platform If TE1...

Page 24: ...hese components 1 Rotor 2 Stator Assembly Use hoist and lifting strap to care fully disassemble reassemble generator Do not damage rotor or stator windings during this procedure Mark electrical leads...

Page 25: ...rotor or stator windings during this procedure Mark electrical leads and remove brush holder assembly before dis assembling unit Reassemble generator parts using torque values in table Reconnect all...

Page 26: ...ntact distributor for more information The following is a list of all diagrams for models covered by this manual Model Serial Or Style Number Circuit Diagram Wiring Diagram 4 kW Generator ME131503R an...

Page 27: ...TM 268 819 Page 25 Belt Driven Generator Figure 10 1 Circuit Diagram For 4 kW Generator And Controller...

Page 28: ...TM 268 819 Page 26 Belt Driven Generator 210 193 C Figure 10 2 Circuit Diagram For 7 5 kW Generator And Controller...

Page 29: ...TM 268 819 Page 27 Belt Driven Generator 203 132 A Figure 10 3 Circuit Diagram For Power Board PC1...

Page 30: ...TM 268 819 Page 28 Belt Driven Generator Figure 10 4 Circuit Diagram For Control Board PC2 Eff w Serial No LC199488 And Following...

Page 31: ...TM 268 819 Page 29 Belt Driven Generator 207 884 C...

Page 32: ...The following is based on the Deutz Tier 4 version of the 4 kW generator 50 Hz Generator Lead Connections Lead Connections GND ENGINE TO 3T 1A STATOR TO CB1 4A STATOR TO CB1 5A STATOR TO RC4 3 6A STAT...

Page 33: ...PLG31 9 9B RC3 B PLG1 8 12B RC2 E PLG1 9 13B RC2 F PLG31 4 15A PLG1 6 TO PLG31 6 16A PLG1 3 TO PLG31 1 17A PLG1 4 TO PLG31 2 21C PLG1 1 TO RC2 A 22C PLG1 2 TO RC2 B 42B RC3 C TO CONNECTION POINT 1 42...

Page 34: ...TM 268 819 Page 32 Belt Driven Generator Notes...

Page 35: ...ff w MD040275R And Following For OM 268 819 Revision A And Following Description Belt Driven Generator TM 268 819A 2014 11 Visit our website at www MillerWelds com 4 kW And 7 5 kW Belt Drive Generator...

Page 36: ...enerator 4000w JLG 1001138565 1 7 264722 Stator Generator 4000w JLG 1001140346 1 7 264718 Stator Generator 4000w JLG 1001140347 1 7 258819 Stator Generator 4000w JLG 1001147436 1 7 258818 Stator Gener...

Page 37: ...ing 4kw Generator JLG 1001150619 1 12 CB1 218782 Supplementary Protector Man Reset 2p 20a 250vac Fr 1 13 139041 Bushing Strain Relief 450 709 Id x 1 115 Mtg Hole 1 207683 Screw 006 32 x 25 Hex Hd Slt...

Page 38: ...sy 4kw 50 60 Hz Includes 1 1 252143 Control Box 4kw Generator 1 2 253045 Bracket Mtg Control Box 2 253044 Cover Control Box 4kw Generator 1 3 C1 253046 Capacitor Polyp Met Film 50 Uf 440 Vac 1 4 Brack...

Page 39: ...Rdl Sgl Row 984 X 2 047 X 591 1 5 255739 Endbell Gen Tensioner Machined JLG1001119250 JLG1001136988 JLG1001155348 1 5 264345 Endbell Gen Tensioner Machined JLG2460050 JLG2460050 1 6 212035 Rotor Asse...

Page 40: ...3 Panel End Shroud JLG2460050 1 20 258645 Panel End Shroud JLG2460048 1 21 258644 Insulator Endbell 1 22 604318 Nut 250 20 50hex 39h Stl Pld Elastic Stop Nut 4 23 268783 Stud Stl 250 20 X 13 312 4 24...

Page 41: ...1 210198 Harness Wrg Control Box Not Shown includes 1 PLG1 PLG31 168071 Housing Plug Pins skts Service Kit 2 7 RC2 210525 Housing Plug Pins skts Service Kit 1 8 RC3 210526 Housing Plug Pins skts Serv...

Page 42: ...TM 268 819 Page 40 Belt Driven Generator Notes...

Page 43: ...TM 268 819 Page 41 Belt Driven Generator Notes...

Page 44: ...er Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA Canada FAX 920 735 4134 Interna...

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