Miller Electric 500DX R Owner'S Manual Download Page 1

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Big Blue 500DX

OM-129 647W

July 1999

Processes

Description

Air Carbon Arc (CAC-A) Cutting

and Gouging

Stick (SMAW) Welding

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Engine Driven Welding Generator

With Optional Equipment:

Visit our website at

www.MillerWelds.com

Summary of Contents for 500DX R

Page 1: ...uly 1999 Processes Description Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding Engine Driven Welding Generator With Optional Equipment Visit our we...

Page 2: ...ner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the works...

Page 3: ...ceptacle RC3 18 4 10 Remote 14 Receptacle RC3 Information Optional 19 4 11 Terminal Strip 2T Connections Optional 19 SECTION 5 OPERATING THE WELDING GENERATOR 20 5 1 Standard Controls See Section 5 2...

Page 4: ......

Page 5: ...when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable...

Page 6: ...touch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high MAGNETIC...

Page 7: ...lammables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see...

Page 8: ...eJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphl...

Page 9: ...ur voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne...

Page 10: ...ssement avant d effec tuer des travaux d entretien Porter des gants et des v tements de protection pour travailler sur un moteur chaud Ne pas toucher mains nues les parties chaudes du moteur ni les pi...

Page 11: ...s Tenir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie Emp cher les tincelles d chappement du moteur de provoquer un incendie Utiliser uniq...

Page 12: ...W Lejeune Rd Mi ami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA...

Page 13: ...Constant Current CC MIG GMAW Welding Constant Voltage CV Time h Hours s Seconds 1 Single Phase 3 Three Phase Read Operator s Manual SECTION 3 SPECIFICATIONS 3 1 Weld Power And Engine Specifications We...

Page 14: ...l occur Do not move or operate unit where it ld ti B 47 1 4 in 1200 mm p could tip C 43 1 4 in 1099 mm D 32 3 4 in 832 mm E 24 15 16 in 633 mm A C F 10 1 2 in 267 mm B C D G 6 1 2 in 165 mm D E 17 5 H...

Page 15: ...it can weld at rated load without overheating Exceeding duty cycle can damage unit and void warranty 60 Duty Cycle At 500 Amperes 6 Minutes Welding 4 Minutes Resting 3 5 AC Auxiliary Power rsb3 1 2 92...

Page 16: ...83 880 A ST 186 173 A The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown A...

Page 17: ...185 B SB 159 101 A The ac power curves show the auxiliary power in amperes avail able at the single phase 120 240 volt or three phase 240 volt terminals A 7 5 KVA KW Single Phase Auxiliary Power Plan...

Page 18: ...ounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI receptacles use GFCI protected extension cord 2 OR 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in...

Page 19: ...ot overfill battery cells Wait ten minutes and check elec trolyte level If necessary add elec trolyte to raise to proper level Reinstall vent caps 6 Battery Charger Read and follow all instruc tions s...

Page 20: ...engine the first time see main tenance label for specifications Fill fuel tank up to 1 2 in 13 mm from top to allow room for expan sion Open fuel shut off valve Do not run out of fuel or air enters f...

Page 21: ...Tools Needed 3 Left Side 2 1 3 4 in 4 7 Selecting Weld Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding Welding Amperes 100 ft 30 m Or Less 150 ft 45 m 200 ft 60 m 250 ft 70 m 300...

Page 22: ...nder nozzle 3 Clamp 4 Fitting 5 Cap 6 Valve Remove cap and clean fitting Install cylinder on fitting Tighten clamp After installing cylinder wait at least 10 minutes before using to let ether particle...

Page 23: ...max of Amper age Voltage control R1 A V D Remote control circuit common Ref ST 800 862 B A V E 0 to 10 volts dc input command signal from remote control Ref ST 800 862 B K Chassis common The remaining...

Page 24: ...OM 129 647 Page 20 SECTION 5 OPERATING THE WELDING GENERATOR 5 1 Standard Controls See Section 5 2 1 10 2 3 11 9 8 7 6 5 4 12 ST 158 630 B Ref ST 158 631 ST 180 933 B...

Page 25: ...witch to select front panel or remote amperage control see example below 4 Manual Stop Control 5 Engine Start Button 6 Ether Starting Aid Switch Optional Push switch up and release while cranking engi...

Page 26: ...OM 129 647 Page 22 5 3 Controls For Models With CV Option See Section 5 4 1 9 2 10 8 7 6 5 4 3 11 ST 158 630 B Ref ST 158 631 Ref ST 185 762 B S 185 440 12 13 14...

Page 27: ...ngine stops 6 DC Ammeter Optional 7 DC Voltmeter Optional 8 Oil Pressure Warning Light Light goes off if oil pressure is too low If light goes off stop engine and check oil level 9 Battery Charging Wa...

Page 28: ...3 Circuit Breakers CB1 And CB2 CB1 and CB2 protect RC1 and RC2 from overload If CB1 or CB2 opens RC1 and one half of RC2 does not work 120 volts may still be present at RC1 Press button to reset brea...

Page 29: ...t weld power speed and press test button to verify GFCI is working properly Australian And South African Receptacle Options 2 240 V 10 A AC Australian Receptacle RC1 3 240 Volt 13 A AC South African R...

Page 30: ...solated Neutral Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be dis connected from neutral to meet applicable electrical codes 9 User Supplied Leads 10 Load Terminals Connect le...

Page 31: ...r From Fuel System OIL Full FUEL WATER 50 h Clean Air Filter See Section 7 3 Clean And Tighten Weld Terminals 100 h Clean And Tighten Battery Connections Change Oil See Section 7 4 Change Oil Filter S...

Page 32: ...see Owner s Manual Air Filter Element MILLER 020 319 Donaldson P181052 Fram CAK 253 Alternator Belt Gates 7425 Deutz 0223 5179 Blower Belt MILLER 064 690 Deutz 223 5531 Gates N7500 Avoid recirculatio...

Page 33: ...ement 4 Plastic Fins 5 Housing To clean air filter Wipe off cap and housing Remove cap and dump out dust Wipe dust from inside cap and housing with damp cloth Remove element and reinstall cap Do not c...

Page 34: ...ws To replace primary fuel filter Close shutoff valve and turn filter counterclockwise Remove filter Apply thin coat of fuel to gasket on new filter Install new filter and turn clockwise Open shutoff...

Page 35: ...rol Lever Turn screw in until screw touches lever Tighten lock nut on screw and reinstall plastic cap Close side door 1 3 8 in 2 4 3 5 Right Side 6 RPM 1850 Tools Needed Engine Speed No Load Weld Powe...

Page 36: ...than 1 2 in 13 mm belt is okay If not okay adjust belt tension To adjust belt tension 4 Hex Nuts 2 5 Alternator Bracket Loosen nuts Pivot alternator until belt is tight Tighten nuts Recheck tightness...

Page 37: ...e manual to replace or tighten belt If belt breaks or becomes loose safety shutdown stops engine Correct problem then reset safety shutdown as follows 2 Rod 3 Stop 4 Bracket 5 Handle Pull handle towar...

Page 38: ...reproof material Stop engine and let cool Reinstall cleanout plug Tools Needed 3 2 1 3 8 in 7 10 Overload Protection For Models With CV Option 1 Circuit Breaker CB3 CB3 protects the 115 volt ac output...

Page 39: ...e speed and adjust if necessary see Section 7 5 Check optional CC CV switch position Low open circuit voltage Check engine speed and adjust if necessary see Section 7 5 Check optional CC CV switch pos...

Page 40: ...switch in Remote position and connect remote contactor to optional Remote 14 receptacle RC3 or terminal strip 2T see Sections 4 10 and 4 11 Place optional CC CV switch in CC position see Section 5 3 H...

Page 41: ...OM 129 647 Page 37 Trouble Remedy Periodically recharge battery approximately every 3 months Engine uses oil during run in period wetstacking occurs Dry engine see Section 9...

Page 42: ...OM 129 647 Page 38 Notes...

Page 43: ...OM 129 647 Page 39 SECTION 8 ELECTRICAL DIAGRAMS 180 941 A Figure 8 1 Circuit Diagram For Welding Generator Standard Models...

Page 44: ...OM 129 647 Page 40 Figure 8 2 Circuit Diagram For Welding Generator Models With CV Option...

Page 45: ...OM 129 647 Page 41 184 954 C...

Page 46: ...er than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generator is kept loaded dur ing run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the ex...

Page 47: ...load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adj...

Page 48: ...h correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid swi...

Page 49: ...ble Insulated Equipment OR 2 Be sure equipment has this symbol and or wording 3 1 10 2 Grounding Generator To Truck Or Trailer Frame S 0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding...

Page 50: ...esistive Load Equipment with a motor is a non resistive load and requires approx imately six times more power while starting the motor than when run ning see Section 10 8 3 Rating Data Rating shows vo...

Page 51: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100...

Page 52: ...HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1...

Page 53: ...tor Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code...

Page 54: ...quate amperage capacity to cord Follow all applicable codes and safety practices Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping th...

Page 55: ...0 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GF...

Page 56: ...12 13 14 15 16 17 18 19 20 21 22 23 6 7 6 7 10 24 25 26 70 69 66 65 64 74 75 76 77 78 79 80 81 82 83 84 85 86 Fig 11 5 87 Fig 11 6 Fig 11 7 88 89 90 91 92 93 Fig 11 2 96 97 98 99 100 101 94 95 Hardwa...

Page 57: ...OM 129 647 Page 53 ST 048 455 AA 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 46 47 48 49 50 45 51 52 53 55 54 56 57 59 60 61 62 63 64 65 66 67 68 Fig 11 3 69 70 71 72 73 58 102...

Page 58: ...83 553 BASE filter fuel w adapter 1 24 145 282 FITTING hose brs barbed elb M 5 16tbg x 1 4NPT 1 25 062 342 SEPARATOR fuel filter water 1 26 116 707 SUPPORT front engine 1 27 010 875 CLAMP muffler 2 00...

Page 59: ...1 79 2T 038 601 BLOCK term 30A 9P 1 80 184 499 BRACKET mtg terminal strip 1 PLG21 168 071 CONNECTOR SOCKETS 1 81 603 107 HOSE nprn slit bk 156 ID x 343 OD order by ft 1ft 82 053 967 INSULATION rectif...

Page 60: ...29 647 Page 56 1 3 4 7 9 10 11 9 14 16 17 18 19 20 21 22 ST 048 457 N 2 Fig 11 4 5 6 8 12 13 15 Hardware is common and not available unless listed Figure 11 2 Panel Front w Components CC Model Illustr...

Page 61: ...25 234 PLUG str grd 2P3W 15A 250V Arrow Hart 5666V 9 PB1 046 433 SWITCH PB MC NO w black cap 1 10 180 904 PLATE ident control rating CC model 1 10 185 763 PLATE ident control rating CC CV model 1 11 0...

Page 62: ...OM 129 647 Page 58 Figure 11 3 Generator SD 048 456 E Hardware is common and not available unless listed 1 2 4 5 6 4 3 7 8 9 11 12 13 10 14 16 15 18 19 20 17 14 21 23 22 24 26 27 28 29 25...

Page 63: ...BAFFLE air gen 1 17 083 751 ROTOR gen consisting of 1 18 024 617 RING retaining external 1 19 053 390 BEARING ball 1 20 083 748 FAN rotor 1 21 044 374 STATOR excitor CC model 1 21 180 684 STATOR exci...

Page 64: ...0thk 1 12 011 007 SPRING pressure 1 13 011 018 CONTACT stationary 9 14 172 702 CONTACT stationary switch consisting of 6 15 011 018 CONTACT stationary 2 16 171 856 SPACER contact 250thk 1 17 011 095 C...

Page 65: ...S 1 15 134 201 STAND OFF support PC card 11 16 PC2 185 747 CIRCUIT CARD ASSEMBLY voltage 1 17 RC1 115 092 CONNECTOR SOCKETS 1 18 PC3 150 415 CIRCUIT CARD ASSEMBLY CONNECTOR 1 19 185 761 COVER CV contr...

Page 66: ...x 1 750 hex collar 1 10 010 913 WASHER flat brs 1 11 1T 038 639 BLOCK terminal 30A 6P 1 12 164 617 CLIP wiring 2 13 D1 189 701 DIODE CAPACITOR BOARD 1 14 C8 170 674 CAPACITOR BOARD 1 15 R6 030 844 RE...

Page 67: ...800V 3 6 2T 038 621 TERMINAL BLOCK 30A 4P 1 7 CR2 044 588 RELAY encl 12VDC 3PDT 1 8 D1 189 701 DIODE CAPACITOR BOARD 1 9 D8 192 307 KIT diode w washers 1 10 C8 170 674 CAPACITOR BOARD 1 ST 801 852 1 2...

Page 68: ......

Page 69: ...hes Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Miller s True Blue Limited Warranty shall not apply to 1 Items furnished by Miller but manufactured by others such as engine...

Page 70: ...ss City State Zip Please complete and retain with your personal records Always provide Model Name and Serial Style Number Contact your Distributor for To locate distributor nearest you call 1 800 4 A...

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