Miller Electric Legend AEAD-200LE Technical Manual
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Miller Electric Legend AEAD-200LE Technical Manual

Miller Electric Legend AEAD-200LE Technical Manual

Cc ac/dc welding generator for smaw, gmaw, gtaw welding
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TECHNICAL MANUAL
Weld
Welding
Output
Mode
Range
CC/AC
35 – 225 A
CC/DC
25 – 200 A
cover_tm 4/95 – ST-140 091-E
Service And Parts
Miller Legend
(Formerly The Legend
CC AC/DC Welding Generator For SMAW, GMAW, GTAW Welding
Rated
Maximum
Welding
Open-Circu
Output
it Voltage
225 A, 25 V,
100% Duty
80
Cycle
200 A, 25 V,
100% Duty
72
Cycle
1996 MILLER Electric Mfg. Co.
February 1996
Effective With Serial No. JH242114
AEAD-200LE)
Auxiliary Power
Fuel Capacity
Rating
Single-Phase,
5 kVA/kW, 42/21 A,
120/240 V AC, 60 Hz
And
And
7.5 gal (28 L) Tank
7 5 gal (28 L) Tank
Single-Phase,
1 kVA/kW, 9 A,
115 V AC, 100 Hz
Form: TM-428
Engine
Onan P218 Air-Cooled,
Two-Cylinder, Four-Cycle,
Two-Cylinder, Four-Cycle,
Gasoline Engine
PRINTED IN USA

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Summary of Contents for Miller Electric Legend AEAD-200LE

  • Page 1 7.5 gal (28 L) Tank 200 A, 25 V, Gasoline Engine Single-Phase, 100% Duty CC/DC 25 – 200 A 1 kVA/kW, 9 A, Cycle 115 V AC, 100 Hz 1996 MILLER Electric Mfg. Co. cover_tm 4/95 – ST-140 091-E PRINTED IN USA...

  • Page 2: Table Of Contents

    WHO DO I CONTACT FOR HELP? CALL: FAX: WRITE: Miller Customer Service 800-637-2348 (in USA), Miller Electric Mfg. Co. Department at P.O. Box 1079 414-735-4505 414-735-4136 (outside USA) Appleton, WI 54912 USA Always provide Model Name and Serial or Style Number...
  • Page 3 SECTION 7 – DISASSEMBLY AND REASSEMBLY ......... . 7-1.

  • Page 5: Section 1 - Safety Precautions For Servicing

    SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING safety_rtm1 4/95 1-1. Symbol Usage Marks a special safety message. Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Means NOTE; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

  • Page 6: Emf Information

    HOT PARTS can cause severe burns. HIGH-FREQUENCY RADIATION interfere with radio navigation, safety 1. Allow cooling period before servicing. services, computers, 2. Wear protective gloves and clothing when working on a hot engine. communications equipment. 1. Have only qualified persons familiar with ELECTRIC SHOCK HAZARD...

  • Page 7: Section 2 - Installation

    SECTION 2 – INSTALLATION 2-1. Installing Welding Generator Movement Airflow Location 18 in Do Not Lift Unit From End (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in 18 in (460 mm) (460 mm) Grounding Generator Base Metal Vehicle Frame Equipment Grounding GND/PE...

  • Page 8: Fuel Consumption

    2-3. Fuel Consumption SB-115 572 2-4. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Engine stops if oil pressure gets 1/2 in too low. (13 mm) Full Full ST-140 091-E / Ref. ST-151 983 TM-428 Page 4 Miller Legend...

  • Page 9: Connecting The Battery

    2-5. Connecting The Battery Connect (–) cable last. – Tools Needed: 3/8, 1/2 in Ref. ST-144 839-F / Ref. ST-168 046 / Ref. S-0756-D 2-6. Connecting To Weld Output Terminals Use ONLY one set of termi- nals at a time. Disconnect weld cables from set of weld output terminals not in use.

  • Page 10: Selecting Weld Cable Sizes

    2-7. Selecting Weld Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) Or Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m) Welding...

  • Page 11: Section 3 - Operating Welding Generator

    SECTION 3 – OPERATING WELDING GENERATOR 3-1. Front Panel Controls Using Idle Lock Switch RUN/IDLE 1860 rpm LOCK (Power/Idle) RUN/IDLE No Load: 1860 rpm (Power/Idle) Load: UNLOCK 3000 rpm (Weld) 3000 rpm (Weld) UNLOCK LOCK Ref. ST-168 046 Engine Control Switch S2 Use control to change engine air-fuel mix.

  • Page 12: Remote Control (Optional)

    3-2. Remote Control (Optional) Weld output terminals are energized when Remote Control switch S4 is in Pan- el/On position and engine is running. Remote 14 Receptacle RC1 Connect optional remote control to RC1 (see Section 2-8). In Example: Min = 70 A DC Percentage Of Range = 50% Max = 88 A DC (50% of 70 to 105) Max (88 A DC)

  • Page 13: Volt-Ampere Curves

    3-4. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of other settings fall between the curves shown. SB-115 529-A / SB-115 528-A Miller Legend TM-428 Page 9...

  • Page 14: Section 4 - Operating Auxiliary Equipment

    SECTION 4 – OPERATING AUXILIARY EQUIPMENT 4-1. 100 Hz Auxiliary Power Receptacle And Circuit Breaker Do not operate 50/60 Hz or 60 Hz equipment from 100 Hz receptacle. 115 V 9 A 100 Hz AC Recep- tacle RC4 Receptacle supplies single-phase power at weld speed only.

  • Page 15: 60 Hz Auxiliary Power Receptacles And Circuit Breakers

    4-3. 60 Hz Auxiliary Power Receptacles And Circuit Breakers For 60 Hz For 60 Hz Auxiliary Power Auxiliary While Welding Power Only LOCK UNLOCK RUN/IDLE RUN/IDLE PANEL PANEL Ref. ST-168 046 If unit does not have GFCI recep- tacle Reset button pops out and the circuit Circuit Breaker CB2 tacles, use GFCI-protected exten- opens to disconnect the faulty equipment.

  • Page 16: Section 5 - Theory Of Operation

    SECTION 5 – THEORY OF OPERATION Engine Supplies force to turn revolving fields. Revolving Fields (Rotor) Turn at 1860 rpm maximum for pow- er/idle and 3000 rpm maximum for Remote Control weld. The speed and excitation cur- Switch S4 rent of the field coils determine volt- ages in stator windings.
  • Page 17 13 Remote Control Switch S4 Selects Panel or remote amperage 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 Provide connection points and power for auxiliary equipment.
  • Page 18 NOTES TM-428 Page 14 Miller Legend...

  • Page 19: Section 6 - Troubleshooting

    SECTION 6 – TROUBLESHOOTING 6-1. Troubleshooting Tables A. Welding See Sections 6-2 and 6-3 for test points and values and Section 10 for parts location. Trouble Remedy No weld output. Check fuse F1, and replace if necessary (see Section 8-6). Check integrated rectifier SR2, and replace if necessary.
  • Page 20 B. 50 Or 60 Hz Auxiliary Power Trouble Remedy No auxiliary power output at recep- Run engine at power/idle speed. tacles RC1, RC2, or RC3. Reset circuit breakers CB1 and CB2. Effective with Serial No. KE629034, also reset circuit breakers CB5 and CB7 (see Section 4-3).
  • Page 21 D. Engine Trouble Remedy Engine will not start. 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. Engine starts but stops as soon as En- Check oil level (see Section 2-4).

  • Page 22: Troubleshooting Circuit Diagram For Welding Generator

    6-2. Troubleshooting Circuit Diagram For Welding Generator Resistance Values Test Equipment Needed: Tolerance – 10% unless specified Condition – 70 F (21 C); cold machine (no warm-up) Wiring Diagram – see Section 9 Stop engine before checking resistance 29 ohms 34 ohms 35 ohms 2 ohms...
  • Page 23 Amperage Readings Tolerance – 5% unless specified Condition – 70 F (21 C); cold machine (no warm-up); no load 3 amps dc Voltage Readings 1.8 amps dc (R1 at min.) 3.1 amps dc (R1 at max.) Tolerance – 10% unless specified Condition –...

  • Page 24: Troubleshooting Circuit Diagram For Welding Generator With Optional Remote Control

    6-3. Troubleshooting Circuit Diagram For Welding Generator With Optional Remote Control Resistance Values Test Equipment Needed: Tolerance – 10% unless specified Condition – 70 F (21 C); cold machine (no warm-up) Wiring Diagram – see Section 9 Stop engine before checking resistance 29 ohms...
  • Page 25 Amperage Readings Tolerance – 5% unless specified Condition – 70 F (21 C); cold machine (no warm-up); no load 3 amps dc Voltage Readings 1.8 amps dc (R1 at min.) 3.1 amps dc (R1 at max.) Tolerance – 10% unless specified Condition –...

  • Page 26: Waveforms For Sections 6-2 And 6-3

    6-4. Waveforms For Sections 6-2 And 6-3 2 ms 50 V 2 ms 10 V A. DC Open-Circuit Voltage, Ampere Ranges B. DC Weld Output, 25 Volts DC, 100 Am- Switch S5 In Max Position peres, Ampere Range Switch S5 In 70-105 Position (Resistive Load) 5 ms 50 V 5 ms 20 V...

  • Page 27: Idle Control Board/Module Pc1 Testing Information

    6-5. Idle Control Board/Module PC1 Testing Information Be sure plugs are secure before testing. See Section 6-6 for specif- ic values during testing. Idle Control Board PC1 (Prior To Serial No. JH300534) Idle Module PC1 (Effective With Serial No. JH300534) Test Equipment Needed: Ref.

  • Page 28: Troubleshooting Flowcharts For Idle Control Board/Module Pc1

    6-6. Troubleshooting Flowcharts For Idle Control Board/Module PC1 Engine does not go to power/idle rpm Engine does not go to weld rpm with with no weld load applied. load applied. Connect meter (DC) between Connect meter (AC) between terminal B (+) and terminal E (–). terminal G and terminal E.
  • Page 29 Engine does not go to weld rpm with Control Relays CR3 and CR4 do not Engine Control switch S2 in Run position. energize at idle rpm (See Section 5 for CR3 and CR4 information) Connect meter (DC) between Connect meter (DC) between terminal A (+) and F (–) prior to terminals D (+) and E (–).

  • Page 30: Voltage Regulator Board Pc2 Testing Information Prior To Serial No. Ke604176

    6-7. Voltage Regulator Board PC2 Testing Information Prior To Serial No. KE604176 Be sure plugs are secure before testing. See Section 6-8 for specif- ic values during testing. Voltage Regulator Board PC2 Terminals A Thru G Test Equipment Needed: Ref. ST-800 698-A / SA-099 497-B 6-8.

  • Page 31: Voltage Regulator Board Pc2 Testing Information Effective With Serial No. Ke604176

    6-9. Voltage Regulator Board PC2 Testing Information Effective With Serial No. KE604176 Be sure plugs are secure before testing. See Section 6-10 for spe- cific values during testing. Voltage Regulator Board PC2 Receptacle RC1 Test Equipment Needed: Ref. ST-800 698-A / SA-160 889-A 6-10.

  • Page 32: Optional Remote Control Board Pc3 Testing Information

    6-11. Optional Remote Control Board PC3 Testing Information Be sure plugs are secure before testing. See Section 6-12 for spe- cific values during testing. Remote Control Board PC3 Receptacle RC1 Test Equipment Needed: Ref. ST-800 698-A / ST-115 941-L / SA-138 247 6-12.

  • Page 33: Optional Remote Capacitor Board Pc5 Testing Information Effective With Serial No. Kd346698

    6-13. Optional Remote Capacitor Board PC5 Testing Information Effective With Serial No. KD346698 Be sure plugs are secure before testing. See Section 6-14 for spe- cific values during testing. Capacitor Board PC5 Remote 14 Receptacle RC1 Receptacle RC2 Terminal K Test Equipment Needed: Ref.

  • Page 34: Replacing Brushes And Cleaning Slip Rings

    6-15. Replacing Brushes And Cleaning Slip Rings A. Checking Brushes And Cleaning Slip Rings Stop engine and allow to cool. Brush Holder Retaining Bar Brush Holder Bracket Remove brush holder bracket. Keep hardware for reinstallation. Brush Holder Brush With Spring Brush Holder Cap Mark and disconnect leads at caps, and remove brushes from...
  • Page 35 B. Adjusting Brush Position Stop engine. After installing brushes, adjust brush position as follows: Brush Holder Brass Sleeve Brush Slip Ring Loosen brush holder bracket mounting hardware. Move bracket until brass sleeves are positioned as shown. Tighten hardware. Reinstall side panels and cover. If operation is still not okay, have a qualified machine shop turn and polish slip rings.

  • Page 36: Checking Unit Output After Servicing

    6-16. Checking Unit Output After Servicing Check engine speeds, and adjust if necessary (see Section 8-5). 115 VAC 100 Hz Receptacle With no load applied and engine running at weld rpm, there should be 128 to 132 volts ac present at RC4.

  • Page 37: Section 7 - Disassembly And Reassembly

    SECTION 7 – DISASSEMBLY AND REASSEMBLY 7-1. Disassembly Of Unit Use Section 6-1 to determine if trouble is in rotor, stator, engine or a combination of these compo- nents. Remove sheet metal panels from unit. Disconnect negative (–) bat- tery cable from battery. Remove spark plugs.

  • Page 38: Disassembly Of Generator

    7-2. Disassembly Of Generator Hardware may differ from that shown. Torques: Prior To Serial No. KD523655 Effective With Serial No. KD523655 15 ft lb (20 N 15 ft lb (20 N 30 ft lb (41 N 20 ft lb (27 N 25 ft lb (34 N 25 ft lb (34 N 15 ft lb (20 N...

  • Page 39: Section 8 - Maintenance

    SECTION 8 – MAINTENANCE 8-1. Routine Maintenance Stop engine before maintaining. See also Engine Manual and mainte- Recycle engine nance label. Service engine more often fluids. during severe conditions. 8 Hours Check Fluid Wipe Up Levels. Spills See Section 2-4 Full 20 Hours Check And...

  • Page 40: Maintenance Label

    8-2. Maintenance Label ONAN P218 GAS ENGINE See Engine Manual for complete engine care. Give engine Specification and Serial Number when ordering parts. To Drain Oil: +100 Push And Check Turn CCW daily. 1/2 in. ID Hose Pull Recommended Oil .

  • Page 41: Servicing Air Cleaner

    8-3. Servicing Air Cleaner Do not run engine without air cleaner or with dirty ele- ment. Stop engine. Precleaner Wash precleaner with soap and water solution. Allow precleaner to air dry completely. Spread 1 tablespoon SAE 30 oil evenly into precleaner. Squeeze out excess oil.

  • Page 42: Changing Engine Oil, Oil Filter, And Fuel Filter

    8-4. Changing Engine Oil, Oil Filter, And Fuel Filter Stop engine and allow to cool. Oil Drain Valve 1/2 ID x 12 in Hose Oil Filter Change engine oil and filter ac- cording to engine owner’s manual. Close valve and valve cap before adding oil and run- ning engine.

  • Page 43: Adjusting Engine Speed

    8-5. Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer. See table for proper no load speeds. If necessary, adjust speeds as fol- lows: Start engine, and place Engine Control switch in Run/Idle position. Turn Fine Amperage control to 100.

  • Page 44: Overload Protection

    8-6. Overload Protection Stop engine. Circuit Breaker CB4 (Internal – Not Shown) CB4 protects the unit from over- load due to an obstructed throttle solenoid. If CB4 opens, engine speed drops to power/idle rpm for about 10 seconds before automati- cally resetting.

  • Page 45: Section 9 - Electrical Diagrams

    SECTION 9 – ELECTRICAL DIAGRAMS The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside machine case or contact factory for actual circuit, if needed. The following is a list of all diagrams for models covered by this manual. To order a copy, proceed as follows: Know unit Model and Serial or Style Number.
  • Page 46 SC-114 477-A Figure 9-1. Circuit Diagram For Miller Legend Without Remote Control Effective With Serial No. JH242114 Thru JH300533 TM-428 Page 42 Miller Legend...
  • Page 47 SC-168 053-A Figure 9-2. Circuit Diagram For Miller Legend Without Remote Control Effective With Serial No. KE629034 And Following Miller Legend TM-428 Page 43...
  • Page 48 Coat terminals with dielectric grade, nonconductive, electric grease (MILLER Part No. 146 557) or equivalent. Figure 9-3. Wiring Diagram For Miller Legend Without Remote Control Effective With Serial No. KE629034 And Following TM-428 Page 44 Miller Legend...
  • Page 49 SD-168 051-B Miller Legend TM-428 Page 45...
  • Page 50 SC-115 947-A Figure 9-4. Circuit Diagram For Miller Legend With Remote Control Effective With Serial No. JH242114 Thru JH300533 TM-428 Page 46 Miller Legend...
  • Page 51 SC-168 054-A Figure 9-5. Circuit Diagram For Miller Legend With Remote Control Effective With Serial No. KE629034 And Following Miller Legend TM-428 Page 47...
  • Page 52 SB-113 710 Figure 9-6. Circuit Diagram For Idle Control Board PC1 Effective With Serial No. JH242114 Thru JH300533 SB-160 891 Figure 9-7. Circuit Diagram For Voltage Regulator Board PC2 Effective With Serial No. KE604176 And Following TM-428 Page 48 Miller Legend...
  • Page 53 OUTPUT POSITIVE SUPPLY+ SB-136 249 Figure 9-8. Circuit Diagram For Optional Remote Control Board PC3 Effective With Serial No. KA840710 And Following SB-148 024-A Figure 9-9. Circuit Diagram For HF Filter Board PC4 Effective With Serial No. KD346698 And Following Miller Legend TM-428 Page 49...
  • Page 54 SB-156 027 Figure 9-10. Circuit Diagram For Optional Capacitor Board PC5 Effective With Serial No. KD346698 And Following TM-428 Page 50 Miller Legend...

  • Page 55: Section 10 - Parts List

    February 1996 Form: TM-428 Effective With Serial No. JH242114 SECTION 10 – PARTS LIST Miller Legend (Formerly The Legend AEAD-200LE) CC AC/DC Welding Generator For SMAW, GMAW, GTAW Welding Miller Legend TM-428 Page 51...
  • Page 56 TM-428 Page 52 Miller Legend...
  • Page 57 Item Dia. Part Description Quantity Mkgs. Figure 10-1. Main Assembly ....++042 132 . . . REMOTE CONTROL, (Figure 10-6) (Prior to JK713332) ....
  • Page 58 Item Dia. Part Description Quantity Mkgs. Figure 10-1. Main Assembly (Continued) ....107 308 . . . HOLD DOWN, bat (Prior to KB113874) ......
  • Page 59 Item Dia. Part Description Quantity Mkgs. Figure 10-2. Generator (Figure 10-1 Item 34) ....013 367 LABEL, warning fan ...........
  • Page 60 Item Dia. Part Description Quantity Mkgs. Figure 10-3. Panel, Front w/Components (Figure 10-1 Item 43) ..RC1,2 . . . 604 176 . . . RECEPTACLE, str dx grd 2P3W 15A 125V (Prior to KE629034) .
  • Page 61 Item Dia. Part Description Quantity Mkgs. Figure 10-3. Panel, Front w/Components (Figure 10-1 Item 43) (Continued) ....039 273 . . . CONNECTOR, circ MS/MET 5 pin sz 16S MS-3106A-16S-8P Amphenol .
  • Page 62 Item Part Description Quantity 005 563 Figure 10-4. Switch, Selector (Figure 10-3 Item 4) ... 005 562 BRACKET, mtg-switch ...........
  • Page 63 Item Dia. Part Description Quantity Mkgs. Figure 10-5. Control Panel, w/Components (Figure 10-1 Item 2) ... . . 038 601 . . . BLOCK, term 30A 9P (Prior to JK713332) .
  • Page 64 Item Dia. Part Description Quantity Mkgs. +042 132 Figure 10-6. Remote Control, Option (Figure 10-1 Item 1) +042 383 ... 136 246 . . . CIRCUIT CARD ASSEMBLY, remote control .
  • Page 65 Dia. Part Description Quantity Mkgs. Figure 10-7. Circuit Card, Voltage Regulator (Figure 10-5 Item 4) 160 888 ... . . 165 411 . . . IC, linear 2904 ........... . .
  • Page 66 Notes...
  • Page 67 Notes...

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