Miller TM-268 Technical Manual
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Miller TM-268 Technical Manual

Miller TM-268 Technical Manual

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TM-268 819A
2014−11
Eff. w/MD040275R And Following
Description
Belt-Driven Generator
4 kW And 7.5 kW
Belt-Drive Generators
Visit our website at
www.MillerWelds.com

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  • Page 1 TM-268 819A 2014−11 Eff. w/MD040275R And Following Description Belt-Driven Generator 4 kW And 7.5 kW Belt-Drive Generators Visit our website at www.MillerWelds.com...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING ........1-1.

  • Page 3: Section 1 − Safety Precautions For Servicing

    D Do not tip battery. D Reinstall doors, panels, covers, or guards when servicing is finished and before starting engine. D Replace damaged battery. D Flush eyes and skin immediately with water. Belt Drive Generator TM-268 819 Page 1...
  • Page 4 Do not use equip- D If notified by the FCC about interference, stop using the equipment ment if leaks are found. at once. TM-268 819 Page 2 Belt Drive Generator...

  • Page 5: California Proposition 65 Warnings

    If cleared by your doctor, then following the above procedures is recom- 3. Do not coil or drape cables around your body. mended. Belt Drive Generator TM-268 819 Page 3...

  • Page 6: Section 2 − Definitions

    2-1. Additional Safety Symbols And Definitions Moving parts can injure. Safe100 2012−08 2-2. Miscellaneous Symbols And Definitions Read Operator’s Circuit Breaker Amperes Volts Manual Alternating Current Positive Negative Output (AC) Protective Earth Time Hours Temperature (Ground) Notes TM-268 819 Page 4 Belt Driven Generator...

  • Page 7: Section 3 − Specifications

    11-1/2 in (292 mm) Width 9 in (229 mm) Width 9-1/2 in (241 mm) Height 13 in (330 mm) Height 4-1/2 in (114 mm) Weight Weight 110 lb (50 kg) 10 lb (5 kg) Belt Driven Generator TM-268 819 Page 5...

  • Page 8: Ac Power Curve

    The ac power curve shows the power in amperes available from the generator. 50HZ 60HZ Current (Amp) 7.5 kW Models 7.5 kW Three−Phase AC AMPERES 6 kW Single−Phase 209 397 / 209 398 / 265 921 AC AMPERES TM-268 819 Page 6 Belt Driven Generator...

  • Page 9: Section 4 − Maintenance And Troubleshooting

    Open cover to access generator. Circuit Breaker CB1 CB1 protects the generator wind- ings from overload. If CB1 opens, generator output stops. Close covers before operating unit. 7.5 kW Model 803 233 / 250 654 Belt Driven Generator TM-268 819 Page 7...

  • Page 10: Section 5 − 4 Kw Models Theory Of Operation

    SECTION 5 − 4 kW MODELS THEORY OF OPERATION Engine Supplies force to turn revolving Terminals field (rotor). AC Or DC Control Circuits 1T, 2T, Revolving Field (Rotor) Generator Output Turns at 3000 rpm (50 Hz) or 3600 rpm (60 Hz). The speed determines Mechanical Coupling voltages in stator windings.

  • Page 11: Section 6 − 7.5 Kw Models Theory Of Operation

    SECTION 6 − 7.5 kW MODELS THEORY OF OPERATION Engine Supplies force to turn revolving Terminal field (rotor). AC Or DC Control Circuits Block Revolving Field (Rotor) Generator Output Turns at 3000 rpm (50 Hz) or 3600 rpm (60 Hz). The speed and excita- Mechanical Coupling tion current of the field coils deter- mine voltages in stator windings.

  • Page 12: Section 7 − Troubleshooting 4Kw Generator

    See Section 7-2 for test points and values and Section 11 and following for parts location. Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit. To avoid charges that are not covered under warranty, troubleshoot and replace components as described. Warranty requests on equipment that could have been repaired in the field or are misdiagnosed may be denied.

  • Page 13: Field Flashing

    1T. Check for output voltage. If output voltage is not present, repeat field flashing procedure. When output voltage is available, stop generator and reinstall cover. Tools Needed: 264 721−TPTM1 Belt Driven Generator TM-268 819 Page 11...

  • Page 14: Section 8 − Troubleshooting 7.5Kw Generator

    See Section 8-2 for test points and values and Section 11 and following for parts location. Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit. To avoid charges that are not covered under warranty, troubleshoot and replace components as described. Warranty requests on equipment that could have been repaired in the field or are misdiagnosed may be denied.
  • Page 15 Replace generator if rotor is open. Check power board PC1 and connections, and replace if indicated (see Section 8-4). Check control board PC2 and connections, and replace if indicated (see Section 8-6). Notes Belt Driven Generator TM-268 819 Page 13...

  • Page 16: Troubleshooting Circuit Diagram For Welding Generator

    No greater than 3.5 amps DC under load See Section 8-6 for PC2 data Ridge denotes Pin 1 Pin 5 - Circuit Common PLG1 Voltage readings taken with PLG1 connected to RC1 on PC2. TM-268 819 Page 14 Belt Driven Generator...
  • Page 17 C to F, E to F, D to F All readings should be 1 ohm. Check with lead 42 lift- ed. Replace generator if windings are shorted to case or open. 210 193-B Belt Driven Generator TM-268 819 Page 15...

  • Page 18: Waveforms For Section 8-2

    A. Generator Open-Circuit Voltage, No Load, 60 Hz 5 ms 5 V B. Pulse Width Modulation (PWM) Signal Between Power Board PC1 And Control Board PC2 (V11 on Troubleshooting Circuit Diagram) Test Equipment Needed: TM-268 819 Page 16 Belt Driven Generator...

  • Page 19: Power Board Pc1 Testing Information

    Revolving field (rotor): +25 volts DC at no load with respect to RC31-4; +75 volts DC at full load with respect to RC31-4 Circuit common Exciter: 150 volts AC with respect to RC31-9 Exciter: 150 volts AC with respect to RC31-8 Belt Driven Generator TM-268 819 Page 17...

  • Page 20: Control Board Pc2 Testing Information

    Enable Line: +12 volts DC when generator is enabled (On); 0 volts DC when generator is not enabled (Off) Revolving field (rotor): +25 volts DC at no load with respect to power board PC1 RC31-4; +75 volts DC at full load with respect to power board PC1 RC31-4 TM-268 819 Page 18 Belt Driven Generator...

  • Page 21: Inspecting Brushes, Replacing Brushes, And Cleaning Slip Rings

    Reinstall belt, brush holder assem- bly, and end panel. 1/4 in (6 mm) Or Less − Replace 7/16 in − 1/2 in (11 − 12 mm) New Tools Needed: 803 275-A Belt Driven Generator TM-268 819 Page 19...

  • Page 22: Setting Control Board Pc2 For 50 Hz Operation

    Switch SW1 is factory set for 60 Hz operation. Change switch position if unit is run at 50 Hz. 60 Hz ON 60 Hz 50 Hz OFF 50 Hz 60 HZ 803 236 / 804 080-A TM-268 819 Page 20 Belt Driven Generator...

  • Page 23: Checking Unit Output After Servicing

    Test Equipment Needed: Pre-Operational Checks Wipe surfaces clean. Check labels; replace labels that are unreadable or damaged. Clean battery terminals. Tighten connections. Clean outside of entire unit. 803 275 Belt Driven Generator TM-268 819 Page 21...

  • Page 24: Section 9 − Disassembly And Reassembly

    SECTION 9 − DISASSEMBLY AND REASSEMBLY 9-1. Disassembling/Reassembling 4 kW Generator Use Section 8-2 to determine if trouble is in stator, rotor, control box, or combina- tion of these components. Rotor Stator Assembly Use hoist and lifting strap to care- fully disassemble/reassemble generator .

  • Page 25: Disassembling/Reassembling 7.5 Kw Generator

    9-2. Disassembling/Reassembling 7.5 kW Generator Use Section 8-2 to determine if trouble is in stator, rotor, control box, or combina- tion of these components. Rotor Stator Assembly Use hoist and lifting strap to care- fully disassemble/reassemble generator . Do not damage rotor or stator windings during this procedure.

  • Page 26: Section 10 − Electrical Diagrams

    See Table 10-1 7.5 kW Generator MD040275R and following 210 193−C See Table 10-2 Circuit Board PC1 (Power Board) MD040275R and following 203 132-A Circuit Board PC2 (Control Board) MD040275R and following 207 884-C TM-268 819 Page 24 Belt Driven Generator...
  • Page 27 Figure 10-1. Circuit Diagram For 4 kW Generator And Controller Belt Driven Generator TM-268 819 Page 25...
  • Page 28 210 193-C Figure 10-2. Circuit Diagram For 7.5 kW Generator And Controller TM-268 819 Page 26 Belt Driven Generator...
  • Page 29 203 132-A Figure 10-3. Circuit Diagram For Power Board PC1 Belt Driven Generator TM-268 819 Page 27...
  • Page 30 Figure 10-4. Circuit Diagram For Control Board PC2 Eff. w/ Serial No. LC199488 And Following TM-268 819 Page 28 Belt Driven Generator...
  • Page 31 207 884-C Belt Driven Generator TM-268 819 Page 29...
  • Page 32 Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram). Plug PLG31 was previously labeled PLG14. Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-applied grease had been present.
  • Page 33 43B RC3 (A) TO CONNECTION POINT 2 16A PLG1 (3) TO PLG31 (1) 43C PLG31 (3) TO CONNECTION POINT 2 17A PLG1 (4) TO PLG31 (2) 43D PLG1 (7) TO CONNECTION POINT 2 Belt Driven Generator TM-268 819 Page 31...
  • Page 34 Notes TM-268 819 Page 32 Belt Driven Generator...
  • Page 35 TM-268 819A 2014−11 Description Belt-Driven Generator 4 kW And 7.5 kW Belt-Drive Generators Eff w/MD040275R And Following For OM-268 819 Revision A And Following Visit our website at www.MillerWelds.com...

  • Page 36: Section 11 − 4 Kw Model Eff W/Me131503R

    ..1T, 2T . . . 072253 Stud, Connection Single 10−32 X .500 X 1.250 Mtg ....TM-268 819 Page 34 Belt Driven Generator...
  • Page 37 Label, Warning Pinch Points Wordless ......Belt Driven Generator TM-268 819 Page 35...
  • Page 38 ....Housing Plug Pins+Skts, (Service Kit) ......TM-268 819 Page 36 Belt Driven Generator...

  • Page 39: Section 12 − 7.5 Kw Model Eff W/Md040275R

    Block, Stud Connection 6 Position ....... . Belt Driven Generator TM-268 819 Page 37...
  • Page 40 Label Kit. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. TM-268 819 Page 38 Belt Driven Generator...
  • Page 41 Label Kit. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. Belt Driven Generator TM-268 819 Page 39...
  • Page 42 Notes TM-268 819 Page 40 Belt Driven Generator...
  • Page 43 Notes Belt Driven Generator TM-268 819 Page 41...
  • Page 44 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2014 Miller Electric Mfg. Co. 2014−01...

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819a

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