Miller Electric AEAD-200-LE User Manual

February 1996 Form: TM-428

T

Effective With Serial No. JH242114

TECHNICAL MANUAL

Service And Parts

Miller Legend

(Formerly The Legend AEAD-200LE)

CC AC/DC Welding Generator For SMAW, GMAW, GTAW Welding

Welding

Mode

CC/AC 35

CC/DC

cover_tm 4/95 – ST-140 091-E PRINTED IN USA

Weld

Output

Range

– 225 A

25 – 200 A

Rated

Welding

Output

225 A, 25 V

100% Duty

Cycle

200 A, 25 V

100% Duty

Cycle

Maximum

Open-Circu

it Voltage

,

,

Auxiliary Power

Rating

Single-Phase,

80

72

5 kVA/kW

120/240 V AC, 60 Hz

And

Single-Phase,

1 kVA/kW

1

15 V AC, 100 Hz

 1996 MILLER Electric Mfg. Co.

, 42/21 A,

, 9 A,

Fuel Capacity Engine

Onan P218 Air-Cooled,

-

7.5 gal (28 L) T

ank

wo-Cylinder, Four-Cycle,

Gasoline Engine

-

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING 1.

1-1. Symbol Usage 1.
1-2. Servicing Hazards 1.
1-3. EMF Information 2.

SECTION 2 – INSTALLATION 3.

2-1. Installing Welding Generator 3.
2-2. Dimensions, Weights, And Operating Angles 3.
2-3. Fuel Consumption 4.
2-4. Engine Prestart Checks 4.
2-5. Connecting The Battery 5.
2-6. Connecting To Weld Output Terminals 5.
2-7. Selecting Weld Cable Sizes 6.
2-8. Remote 14 Receptacle RC1 Information 6.

SECTION

3 – OPERA

3-1. Front Panel Controls 7.
3-2. Remote Control (Optional) 8.
3-3. Duty Cycle 8.
3-4. Volt-Ampere Curves 9.

SECTION

4 – OPERA

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TING WELDING GENERATOR 7.

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TING AUXILIAR

Y EQUIPMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. 100 Hz Auxiliary Power Receptacle And Circuit Breaker 10.
4-2. AC Auxiliary Power Curve 10.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. 60 Hz Auxiliary Power Receptacles And Circuit Breakers 11.

SECTION 5 – THEOR

Y OF OPERA

TION 12.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.

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SECTION 6 – TROUBLESHOOTING 15.

6-1. Troubleshooting Tables 15.
6-2. Troubleshooting Circuit Diagram For Welding Generator 18.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6-3. Troubleshooting Circuit Diagram For Welding Generator With Optional Remote Control 20.
6-4. Waveforms For Sections 6-2 And 6-3 22.
6-5. Idle Control Board/Module PC1 Testing Information 23.
6-6. Troubleshooting Flowcharts For Idle Control Board/Module PC1 24.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . .

6-7. Voltage Regulator Board PC2 Testing Information Prior To Serial No. KE604176 26.
6-8. Voltage Regulator Board PC2 Test Point Values Prior To Serial No. KE604176 26.
6-9. Voltage Regulator Board PC2 Testing Information Effective With Serial No. KE604176 27.
6-10. Voltage Regulator Board PC2 Test Point Values Effective With Serial No. KE604176 27.
6-11. Optional Remote Control Board PC3 Testing Information 28.
6-12. Optional Remote Control Board PC3 Test Point Values 28.

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-13. Optional Remote Capacitor Board PC5 Testing Information Effective With

Serial No. KD346698 29.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-14. Optional Remote Capacitor Board PC5 Test Point Values Effective With

Serial No. KD346698 29.
6-15. Replacing Brushes And Cleaning Slip Rings 30.
6-16. Checking Unit Output After Servicing 32.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WHO DO I CONTACT FOR HELP?

H CALL:

Miller Customer Service

Department at

414-735-4505

H FAX:

800-637-2348
or
414-735-4136 (outside USA)

(in USA),

H WRITE:

Miller Electric Mfg. Co.
P

.O. Box 1079

Appleton, WI 54912 USA

.

. . . . . . .

. . . . . . . .

. .

. . .

Always provide Model Name and Serial or Style Number

OM-428N 1/96 – SPM-428C 6/94

SECTION 7 – DISASSEMBL

7-1. Disassembly Of Unit 33.
7-2. Disassembly Of Generator 34.

SECTION 8 – MAINTENANCE 35.

8-1. Routine Maintenance 35.
8-2. Maintenance Label 36.
8-3. Servicing Air Cleaner 37.
8-4. Changing Engine Oil, Oil Filter, And Fuel Filter 38.
8-5. Adjusting Engine Speed 39.
8-6. Overload Protection 40.
8-7. Inspecting And Cleaning Optional Spark Arrestor 40.

SECTION 9 – ELECTRICAL DIAGRAMS 41.

Y AND REASSEMBL

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Y 33.

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SECTION 10 – PARTS LIST 51.

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SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING

safety_rtm1 4/95

1-1. Symbol Usage

Y

Means Warning! Watch Out! There are possible hazards with this
procedure!

The possible hazards are shown in the adjoining symbols.

This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING

and HOT PARTS hazards. Consult symbols and related instructions below for necessary

PARTS,
actions

to avoid the hazards.

1-2. Servicing Hazards

WARNING

The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.

Only qualified persons should service, test, maintain, and repair this unit.
During servicing, keep everybody, especially children, away.

Marks a special safety message.

.

Means NOTE; not safety related.

ELECTRIC SHOCK can kill.

1. Do

not touch live electrical parts.

2. Stop

3. Insulate yourself from ground by standing or

4.

5. When

engine before testing or repairing unit unless
the procedure specifically requires an energized
unit.

working on dry insulating mats big enough to

contact with the ground.

prevent
Do not leave live unit unattended.

testing live unit, use
Do not put both hand inside unit. Keep one
free.

the one-hand method.

hand

MOVING PARTS can cause injury.

1. Keep

2. Have only qualified people remove guards or

3. Keep hands, hair, loose clothing, and tools away

4. Before

5. Block

6.

FLYING

away from moving

and

rotors.

covers for maintenance and troubleshooting as
necessary.

moving parts.

from

working on generator
or injectors to keep engine from kicking back or
starting.

flywheel so that it will not

on

generator components.

Reinstall panels or
servicing is finished and before starting engine.

PIECES

parts such as fans, belts,

, remove spark plugs

turn while working

guards and close doors when

OF MET

AL or DIRT can

cause injury.

1. Always wear safety glasses with side shields or
face

shield during servicing.

2. Be

careful not to short metal tools, parts, or wires

together

during testing and servicing.

STATIC

ELECTRICITY

can damage parts

on circuit boards.

1. Put on grounded wrist strap BEFORE handling
boards

or parts.

2. Use proper static-proof bags to store, move, or
ship

PC boards.

ENGINE EXHAUST GASES can kill.

1. Do

not breathe exhaust fumes.

2. Use in open, well-ventilated areas, or vent
exhaust outside and away from any building air
intakes.

ENGINE FUEL can cause fire or
explosion.

1. Stop

2. Do not fuel while smoking or near sparks or

3. Do

engine before fueling.

flames.

not overfill tank; clean up any spilled fuel.

BATTERY EXPLOSION can BLIND and
INJURE.

1. Always wear a face shield when working on a
battery.

2. Stop engine before disconnecting or connecting
battery

cables.

3. Do

not allow tools to cause sparks when working

on a battery

4. Do

not use welder to charge batteries or jump

vehicles.

5. Observe

.

start

correct polarity (+ and –) on batteries.

BATTERY ACID can BURN SKIN.

1. Do

not tip.

2.

Replace damaged battery
Flush eyes and skin immediately with water

3.

.

.

STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.

1. Check coolant level when
scalding.

2. If the engine is warm and checking is needed,

3. Wear

4. Turn cap slightly and let pressure escape slowly

steps 3 and 4.

follow

safety glasses and gloves and put a rag over

cap.

completely removing cap.

before

engine is cold to avoid

FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.

1. Use equipment of adequate capacity to lift
components.

a lifting eye to lift unit only, NOT running gear

2. Use
gas cylinders, or any other accessories.

3.

Securely attach components to lifting

equipment.

,

Miller Legend

TM-428 Page 1

HOT PARTS can cause severe burns.

1. Allow

2. Wear

cooling period before servicing.
protective gloves and clothing when working

on

a hot engine.

ELECTRIC SHOCK HAZARD from
incorrect use of test equipment.

1. Stop engine before making or changing meter
connections.

lead

2. At

least one meter lead should be a self-retaining

spring

clip such as an alligator clamp.

3.

Read instructions for test equipment.

MAGNETIC FIELDS FROM HIGH
CURRENTS can affect pacemaker
operation.

1. Pacemaker wearers keep away from servicing

areas

until consulting your doctor

.

UNCONTROLLED TILTING OR TIPPING
OF UNIT can result in personal injury
and equipment damage.

1. Do

not put any body part under unit while lifting.

2. Use adequate blocks to support components as

needed

during job.

PINCH POINTS can injure.

1. Be careful when working on stator and rotor

assemblies.

HIGH-FREQUENCY RADIATION can
interfere with radio navigation, safety
services, computers, and
communications equipment.

1. Have only qualified persons familiar with
electronic

2. The user is responsible for having a qualified
electrician promptly correct any interference
problem

3. If notified by the FCC about interference, stop
using

4. Have the installation regularly checked and
maintained.

5. Keep high-frequency source doors and panels
tightly shut, keep spark gaps at correct setting,
and use grounding and shielding to minimize the
possibility

equipment perform this installation.

resulting from the installation.

the equipment at once.

of interference.

READ INSTRUCTIONS.

1. Use MILLER Testing Booklet (Part No. 150 853)
when

servicing this unit.

2. Consult the Owner’s Manual for welding safety
precautions.

3. Use

only genuine MILLER replacement parts.

4. Reinstall injectors and bleed air from fuel system
according to engine manual.

1-3. EMF Information

Considerations
Electric

The

following is a quotation from the

of

the U.S. Congress, Of

Effects of Power Frequency Electric & Magnetic Fields –
Background Paper

Government Printing Office, May 1989): “. . . there is now a very
large volume of scientific findings based on experiments at the
cellular
establish that low frequency magnetic fields can interact with, and
produce
very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk

or to of

or

avoid potential risks.”

About W

And Magnetic Fields

level and from studies with

changes in, biological systems.

fer clear science-based advice on strategies to minimize

elding And The Ef

fice of T

echnology Assessment,

, OTA-BP-E-53 (Washington, DC: U.S.

animals and people which clearly

fects Of Low

General Conclusions Section

While most of this work is of

Frequency

Biological

To reduce magnetic fields in the workplace, use the following
procedures:

1. Keep

2.

3.

4.

5.

About Pacemakers:

The above procedures are also recommended for pacemaker
wearers.

cables close together by twisting or taping them.
Arrange cables to one side and away from the operator
Do not coil or drape cables around the body
Keep welding power source and cables as far away as

practical.
Connect work clamp to workpiece as close to the weld as

possible.

Consult your doctor for complete information.

.

.

TM-428 Page 2

Miller Legend

SECTION 2 – INSTALLATION

A

2-1. Installing Welding Generator

Movement Airflow Location

Y Do Not Lift Unit From End

18 in

(460 mm)

OR

18 in

(460 mm)

18 in

(460 mm)

OR

18 in

(460 mm)

Grounding

1

OR

Electrically

2

vehicle frame by metal-to-metal
contact.

bond

generator frame to

3

GND/PE

2-2. Dimensions, Weights, And Operating Angles

A

Height 31-5/8

Width 18

Dimensions

in (803 mm)

in (457 mm)

18 in

(460 mm)

1 Generator Base

Metal V

4

2

install1 10/95 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854

Y Do not exceed operating angles while

running

Y Do

tip.

2
3

4
Use #10 AWG or larger insulated

copper

Y If unit does not have GFCI

or engine damage will occur

not move or operate unit where it could

ehicle Frame

Equipment Grounding
Terminal

Grounding Cable

wire.

receptacles, use GFCI-pro-

extension cord.

tected

.

Miller Legend

Engine End

Depth 45

B

A 16-1/2

B 32-3/4

C 13/16

in (1

143 mm)

in (419 mm)

in (832 mm)

in (21 mm) Dia.

25°
25°

25°
25°

°

Weight

C

Net 559

Ship 600

lb (254 kg)

lb (272 kg)

TM-428 Page 3

2-3. Fuel Consumption

SB-115 572

2-4. Engine Prestart Checks

1/2 in

(13 mm)

Full

Check

all fluids daily

be

cold and on a level surface.

Engine stops if oil pressure gets

low

.

too

Full

. Engine must

TM-428 Page 4

ST-140 091-E / Ref. ST-151 983

Miller Legend

2-5. Connecting The Battery

Y

Connect (–) cable last.

Tools

Needed:

3/8, 1/2 in

2-6. Connecting To Weld Output Terminals

+

–

Ref. ST-144 839-F / Ref. ST-168 046 / Ref. S-0756-D

Y Use ONLY one set of termi-

nals at a time. Disconnect

cables from

weld
output

terminals not in use.

set of weld

Tools

Miller Legend

Needed:

3/4 in

ST-140 092-B / Ref. ST-168 046

TM-428 Page 5

2-7. Selecting Weld Cable Sizes

B

A

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

Welding

Amperes

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

Weld cable size (A

10 – 60%

Duty Cycle

WG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

60 – 100%

Duty Cycle

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

10 – 100% Duty Cycle

350 ft

(105 m)

2-8. Remote 14 Receptacle RC1 Information

Socket* Socket Information

400 ft

(120 m)

S-0007-D

AJ

K

B

L

C

D

*The remaining sockets are not used.

I

NH

M

G

F

E

ST-140 092-B

A Contact

B 15 volts dc.

C +4.5

D Remote

E 0

K Chassis

closure to B completes 15 volts dc contactor control

circuit.

volts dc output to remote control.

control circuit common.

to +4.5 volts dc input command signal from remote control.

common.

TM-428 Page 6

Miller Legend

SECTION 3 – OPERATING WELDING GENERATOR

3-1. Front Panel Controls

RUN/IDLE

Using Idle Lock Switch

6 7

15

2

3

4

LOCK

RUN/IDLE

UNLOCK

RUN

OR

1 Engine

Control Switch S2

Use switch to start engine, select speed,
and stop engine. In Run/Idle position, en-

runs at power/idle rpm at no load, and

gine
weld/power
iary
engine

2

rpm under weld or 100 Hz auxil

power receptacle load. In Run

runs at weld rpm.

Idle Lock Switch S1

position,

Use switch to lock engine at power/idle
speed (see Table). In Unlock position, En­gine Control switch and optional Remote

switch determine engine speed.

Control
3

Engine Choke Control

1860 rpm

(Power/Idle)

No Load:
1860 rpm

(Power/Idle)

Load:

3000 rpm

(Weld)

3000 rpm

LOCKUNLOCK

(Weld)

Use control to change engine air-fuel mix.
To Start: pull out choke and turn Engine

Control switch to Start position. Release
switch and slowly push choke in when en-

-

gine starts. Do not crank engine while fly-

is turning.

wheel
To Stop: turn Engine Control switch to Off

position.
4 Remote

Control Switch S4

Use switch to select front panel or remote
amperage

5

control (see Section 3-2).

Ampere Ranges Switch S5

Ref. ST-168 046

Use

switch to select weld amperage range.

.

For best arc starts, use lowest amper-

range possible.

age

6

Fine Amperage Control R1

Use

control to select

weld amperage within

the range selected by the Ampere Ranges

Control

switch.

Scale is

ing.

may be adjusted while weld

for reference only

. W

eld output

would be 88 A DC with control settings as

(50% of 70 to 105 A).

shown
7

Engine Hour Meter HM

-

Miller Legend

TM-428 Page 7

3-2. Remote Control (Optional)

Y Weld output terminals are

energized when Remote

1

Control switch S4 is in Pan-

position and engine is

el/On
running.

1 Remote
Connect

RC1

Percentage Of Range = 50%

Max = 88 A DC (50% of 70 to 105)

14 Receptacle RC1

optional remote control

(see Section 2-8).

In Example:

Min = 70

A DC

to

Set Switch

3-3. Duty Cycle

Set Range

Set Percentage

Max (88

Min (70

Duty
minutes
load

Y Exceeding duty cycle can

A DC)

A DC)

Adjust Remote Control

cycle is the percentage of 10

that unit can weld at

without overheating.

damage unit and void war­ranty.

ST-140 092-B

rated

TM-428 Page 8

100% Duty Cycle at 225 Amperes AC

Continuous Welding

SB-115 570

Miller Legend

3-4. Volt-Ampere Curves

The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities

the welding generator

of
other settings fall between the

shown.

curves

. Curves of

Miller Legend

SB-115 529-A / SB-115 528-A

TM-428 Page 9

SECTION 4 – OPERATING AUXILIARY EQUIPMENT

4-1. 100 Hz Auxiliary Power Receptacle And Circuit Breaker

2

1

Y Do not operate 50/60 Hz or

60 Hz equipment from 100

receptacle.

Hz

11

15 V 9 A 100 Hz AC Recep

tacle RC4

Receptacle supplies single-phase
power at weld speed only. Total

available is 1 kV

output
2 Circuit Breaker CB3
CB3 protects receptacle from

overload.
does

If CB3 opens, receptacle

not work.

A/kW.

-

4-2. AC Auxiliary Power Curve

Ref. ST-168 046

SB-115 571

TM-428 Page 10

Miller Legend

4-3. 60 Hz Auxiliary Power Receptacles And Circuit Breakers

4

5 7812

6

3

For 60 Hz

Auxiliary Power

While W

elding

LOCK UNLOCK

RUN/IDLE RUN/IDLE

0 100

PANEL

ON

For 60 Hz

Auxiliary

Power Only

0 100

PANEL

ON

YIf unit does not have GFCI recep-

tacles, use GFCI-protected exten-

cord.

sion

1 120

V 15 A AC

2

120 V 15 A AC Duplex Receptacle RC2

3 240

V 30 A T

Duplex Receptacle RC1

wistlock Receptacle RC3

Receptacles supply 60 Hz single-phase
power at power/idle speed only. Maximum

from each duplex receptacle

output
kVA/kW

. Maximum output from twistlock re

ceptacle is 5 kVA/kW. For 60 Hz auxiliary

set controls as shown in table.

power,
4

120 V 15 A AC Duplex GFCI Recep
tacles GFCI1 And GFCI2 (Optional)

If a ground fault is detected, the GFCI recep

Miller Legend

is is 2.5

-

9

tacle Reset button pops out and the circuit
opens to disconnect the faulty equipment.

for damaged tools, cords, plugs, etc.

Check
connected
reset

.

to the receptacle. Press button to

receptacle and resume operation.

At least once a month, run engine at
power/idle

speed and press T

to verify GFCI is working properly.

5 Circuit Breaker CB5

-

6 Circuit Breaker CB7
CB5 protects RC1 and CB7 protects RC2

overload. If CB5 or CB7 opens, the re

from
ceptacle does not work. Press button to re-

breaker

set

-

7 Circuit Breaker CB1

.

est

button

Ref. ST-168 046

8 Circuit Breaker CB2
CB1 and CB2 protect all the 60 Hz recep-

tacles from overload. If CB1 or CB2 opens,
the 240 volt receptacle and one of the 120
volt receptacles does not work. 120 volts
may still be present at the 240 volt recep-

Press button to reset breaker

tacle.

otal Auxiliary Power Output

9T
Combined output of receptacles limited to

A/kW output of the generator:

the 5 kV
EXAMPLE:

­plex

240
(120

If 10 A is drawn from a 120 V du

receptacle, only 16 A is available at the

V receptacle:

V x 10 A) + (240 V x 16 A) = 5.0 kV

TM-428 Page 1

.

-

A/kW

1

SECTION 5 – THEORY OF OPERATION

1 Engine
Supplies force to turn revolving

fields.
2 Revolving
Turn

at 1860 rpm maximum for pow
er/idle and 3000 rpm maximum for
weld.

The speed and excitation cur
rent of the field coils determine volt
ages in stator windings.

3

Stator Windings

Supply power to exciter, auxiliary
power,

4

Fuse F1

Protects exciter excitation winding

overload.

from
5

Integrated Rectifier SR2

Changes ac output of stator wind­ings

to dc to supply excitation current

to

the exciter revolving field.

6

Control Relay CR5

Energizes
exciter stator to disconnect field
flashing circuit.

Idle Module PC1 And Idle Lock

7

Switch S1

PC1 and S1 control engine speed.
Without
ers engine speed to power/idle rpm.

8 Throttle
Increases

when

energized.
9

Current T

Senses output from either weld or
100 Hz auxiliary power windings,
and signals PC1 to increase to or
maintain

10 Control Relays CR2, CR3, CR4
CR2

energizes at weld rpm to supply

power
CR3 energizes at power/idle rpm to

bypass
CR4 energizes at power/idle rpm to

provide 50/60 Hz auxiliary power
output.

11 Voltage

And T

PC2 monitors 50/60 Hz auxiliary
power
tains

proper output by adjusting

current.
12 Capacitor

14 Receptacle RC1, Remote
Control Board PC3

PC5

protects unit from high frequen

cy.

RC1
and contactor control to unit through
control

Fields (Rotor)

and weld circuits.

when voltage is present in

a signal from CT1, PC1 low

Solenoid TS1

engine speed to weld rpm

ransformer CT1

weld rpm.

to throttle solenoid TS1.

fine amperage control R1.

Regulator Board PC2

ransformer T1

voltage through T1, and main

field

Board PC5, Remote

connects remote amperage

board PC3.

-

-

-

♦

12

Capacitor Board

PC5

And Remote 14

Receptacle RC1

18

Amperage

Control R1

1

-

-

-

8

Engine

Throttle

Solenoid

TS1

7

10

♦

13

Remote Control

Remote 14

♦

12

Remote

Control Board

PC3

Fine

2

Revolving

Fields (Rotor)

5

Integrated

Rectifier SR2

♦

6

Control

Relay

CR5

Idle Module

PC1

Control Relays

CR2, CR3, CR4

Switch S4

Panel

CR3

7

4

Fuse

F1

Idle Lock

Switch S1

11

3

Exciter

Voltage

Regulator

Board PC2

Voltage

Regulator

Stator Windings

9

16

17

60 Hz Auxiliary

Power

100 Hz

Auxiliary

Power

Current

Transformer

Breaker

100 Hz

Auxiliary Power

Receptacle RC4

Weld

CT1

Circuit

CB3

TM-428 Page 12

Miller Legend

19

20

CR4

14 15

Circuit

Breakers
CB1, CB2,
CB5, CB7

Ampere
Ranges

Switch S5

Reactor

AC-Z

11

Transformer

23

T1

Auxiliary Power

Receptacles

RC1, RC2, RC3

50/60 Hz

25

Electrode

Work AC Weld

Output

T erminals

And

13

Remote Control Switch S4

Selects

Panel or remote

control.
14 Circuit Breakers CB1, CB2,

CB5, And CB7

Protect 50/60 Hz auxiliary power
receptacles RC1, RC2, and RC3
from

overload.

15

50/60 Hz Auxiliary Power Re
ceptacles RC1, RC2, And
RC3

Provide connection points and

for auxiliary equipment.

power
16 Circuit Breaker CB3
Protects

100 Hz auxiliary power

ceptacle

RC4 from overload.

17 100 Hz Auxiliary Power Re-

ceptacle RC4

Provides connection point and
power for auxiliary equipment
while

welding.

18

Fine Amperage Control R1

Adjusts

amperage
lected by Ampere Ranges switch
S5.

19 Ampere
Selects coarse range of weld out-

put

from weld stator
20 Reactor AC-Z
Tapped reactor limits weld output

and
21
Changes ac output from weld

windings
22
Smooths out current to dc weld

output
23
Protects unit from high frequency
24

Provide dc weld output.
25

Provide ac weld output.

Ranges Switch S5

provides coarse ranges.
Main Rectifier SR1

to dc.

Stabilizer DC-Z

terminals.

HF Filter Board PC4

Positive (+) And Negative (–)
DC W

eld Output T

Electrode And W
Output T

erminals

amperage

re

within range se

.

erminals

ork AC Weld

-

-

-

.

21

22

Stabilizer

Miller Legend

Main

Rectifier

SR1

DC-Z

HF Filter

Board

PC4

24

Positive (+)

Negative (–) DC

eld Output

W

Terminals

And

AC Or DC Control Circuits
W

eld Current Circuit

Mechanical Coupling

Magnetic Coupling

♦ Optional

TM-428 Page 13

NOTES

TM-428 Page 14

Miller Legend

SECTION 6 – TROUBLESHOOTING

6-1. Troubleshooting Tables

A. Welding

Trouble Remedy

.

See Sections 6-2 and 6-3 for test
points and values and Section 10

parts location.

for

No weld output.

No or erratic weld output.

Check fuse F1, and replace if necessary (see Section 8-6).
Check integrated rectifier SR2, and replace if necessary
Check diode D4, and replace if necessary
Clean slip rings, and install new brushes if necessary (see Section 6-15).
Disconnect leads 21, 23, and 33 from brushes, and check continuity across slip rings. Replace rotor

if necessary.
Check resistance and connections of resistors R2 and R4; R2 and R4 are each 12 ohms

place resistor(s) if necessary
Check

resistance and connections of Fine Amperage Control

R1

if necessary (see Section 3-1).

Disconnect
22

and 29. Replace exciter stator if necessary

For
nections. Replace C5 if necessary.

Check voltage regulator board PC2 and connections, and replace if necessary (see Section 6-9).
Clean and tighten weld connections both inside and outside unit.
Check engine speed, and adjust if necessary (see Section 8-5).
Check

replace if necessary.
Check

connections. Replace AC-Z if necessary.

leads 22 and 29 from SCR/integrated rectifier SR2, and check for continuity between leads

units with optional remote control, check capacitor C5 for a short or open, and check for proper con

to make sure Ampere Ranges switch S5 is not between positions. Check continuity of S5, and

reactor AC-Z for signs of winding failure. Check continuity across windings, and check for proper

. Adjust R2 and R4 according to Section 6-16.

.

.

.

R1; R1 is 0 to 30 ohms ±10%. Replace

±10%.

Re

-

-

No or erratic DC weld output only

Low or high weld output.

Miller Legend

Check

resistance and connections of Fine Amperage control R1; R1 is 0 to 30 ohms ± 10%. Replace

R1 if necessary.
Disconnect leads 21, 23, and 33 from brushes, and check continuity across slip rings. Replace rotor

if necessary.

.

Check modular main rectifier SR1, and replace if necessary
Check stabilizer DC-Z for signs of winding failure. Check continuity across windings, and check for

proper connections. Replace DC-Z if necessary.
Check engine speed, and adjust if necessary (see Section 8-5).
Adjust resistor R4 slider until 128 to 132 volts ac is obtained at 100 Hz receptacle RC4 (see Section

6-16).
Adjust

resistor R2 slider until proper open-circuit-voltage is obtained at

tion

6-16).

Check

resistance

10%.

Replace R3, VR1 module if necessary

Check

reactor AC-Z for signs of winding failure. Check continuity across windings, and check for proper

connections. Replace AC-Z if necessary.

and connections of resistor R3 on suppressor R3, VR1 module; R3 is 1000 ohms

.

.

weld output terminals (see Sec

-

±

TM-428 Page 15

B. 50 Or 60 Hz Auxiliary Power

Trouble Remedy

No auxiliary power output at recep­tacles RC1, RC2, or RC3.

Low auxiliary power output.

Run engine at power/idle speed.

Reset circuit breakers CB1 and CB2. Effective with Serial No. KE629034, also reset circuit breakers
CB5

and CB7 (see Section 4-3).

Check

receptacles RC1, RC2, RC3 for continuity and proper connections. Replace receptacle(s) if nec

essary.
Check

connections to terminal strip 1T
Clean slip rings, and install new brushes if necessary (see Section 6-15).
Check

coil voltage and connections of control relay CR4. Check continuity of coil and condition of
tacts. Replace CR4 if necessary.

Check diode D4, and replace if necessary
Check idle board/module PC1 and connections (see Section 6-5).
Check

control transformer T1 for signs of winding failure. Check continuity across windings, and check
for

proper connections. Check primary and secondary voltages. Replace T1 if necessary

Disconnect leads 21, 23, and 33 from brushes, and check continuity across slip rings. Replace rotor
if necessary.

Disconnect
and
and 52 and 53. Replace stator if necessary

Check connections to terminal strip 1T
Clean slip rings, and install new brushes if necessary (see Section 6-15).

leads 48 and 49

49. Disconnect leads 50, 51, 52, and 53 from stator

from voltage regulator board PC2, and check continuity between leads 48

.

con

.

.

. Check continuity between leads 50 and 51,

.

.

-

-

High auxiliary power output.

C. 100 Hz Auxiliary Power

Trouble Remedy

No

auxiliary power output at receptacle

RC4.

Check integrated rectifier SR2, and replace if necessary
Check

coil voltage and connections of control relay CR3. Check continuity of coil and condition of
tacts. Replace CR3 if necessary.

Check voltage regulator board PC2 and connections, and replace if necessary
Check engine speed, and adjust if necessary
Check voltage regulator board PC2 and connections, and replace if necessary (see Section 6-9).

Run

engine at weld speed.

Reset circuit breaker CB3 (see Section 4-1).
Check receptacle RC4 for continuity and proper connections. Replace receptacle if necessary
Disconnect

93. Replace stator if necessary.
Check diode D4, and replace if necessary

leads 90, 91, 92, and 93 from stator

.

. Check continuity between leads 90 and 91, and 92 and

.

.

.

.

con

-

TM-428 Page 16

Miller Legend

D. Engine

Trouble Remedy

Engine will not start.

Engine starts but
gine Control switch S2 returns to Run
position.

Engine stopped during normal opera­tion.

Battery discharges between uses.

stops as soon as En

Check fuel level (see Section 2-4).
Check battery and engine charging system according to engine manual.
Check continuity of Engine Control switch S2, and replace if necessary
See engine manual.

-

Check

oil
for

Check
manual).

Check
Check

for
Check continuity of Engine Control switch S2, and replace if necessary
Make

3-1).
Prior
Clean battery, terminals and posts with baking soda solution; rinse with clear water
Periodically recharge battery (approximately every 3 months).
Check voltage regulator according to engine manual.

level (see Section 2-4). Check low oil pressure shutdown switch S3 (see engine parts manual

location). S3 should close when engine is running.

and refill crankcase with proper

continuity of Engine Control switch S2, and replace if necessary

oil

level (see Section 2-4). Check low oil pressure shutdown switch S3 (see engine parts manual

location). S3 should close when engine is running.

sure Engine Control switch

to Serial No. KA780044, check fuse F2 and replace if necessary

viscosity oil for operating temperature, if necessary (see engine

S2 is placed in the Of

f position when engine is not in use (see Section

.

.

.

.

.

Engine idles, but does not come up to
weld

speed.

Engine does not return to idle speed.

Unstable or sluggish engine speeds.

Replace battery
W

ait 10 seconds for throttle solenoid circuit breaker CB4 to reset (see Section 8-6).

Place Idle Lock switch S1 in Unlock position (see Section 3-1).
Check continuity and connections of current transformer CT1, and replace if necessary
Check continuity of Engine Control switch S2, and replace if necessary
Check

coil voltage and connections of control relay CR2. Check continuity of coil and condition of
tacts. Replace CR2 if necessary.

Check diode D6 in throttle solenoid TS1 circuit, and replace if necessary
Check resistance at throttle solenoid TS1 terminals. With plunger out, resistance is less than 1 ohm.

With plunger bottomed, resistance is 17 ohms
Check throttle linkage for smooth, non-binding operation.
Check idle board/module PC1 and connections, and replace if necessary (see Section 6-5).
Remove weld load.
Check continuity of Engine Control switch S2, and replace if necessary
Check throttle linkage for smooth, non-binding operation.
Readjust throttle linkage if necessary
T

une-up engine according to engine manual.

.

.

.

con

.

±10%.

.

.

-

Miller Legend

TM-428 Page 17