Miller Electric Big Blue 500 PT Page 3 Owner'S Manual Download

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TABLE OF CONTENTS

SECTION 1

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SAFETY PRECAUTIONS

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READ BEFORE USING

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1-1. Symbol Usage

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1-2. Arc Welding Hazards

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1-3. Engine Hazards

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1-4. Compressed Air Hazards

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1-5. Additional Symbols For Installation, Operation, And Maintenance

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1-6. California Proposition 65 Warnings

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1-7. Principal Safety Standards

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1-8. EMF Information

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SECTION 2

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CONSIGNES DE SÉCURITÉ

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LIRE AVANT UTILISATION

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2-1. Signification des symboles

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2-2. Dangers relatifs au soudage à l’arc

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2-3. Dangers existant en relation avec le moteur

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2-4. Dangers liés à l’air comprimé

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2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

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2-6. Proposition californienne 65 Avertissements

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2-7. Principales normes de sécurité

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2-8. Information EMF

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SECTION 3

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DEFINITIONS

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3-1. Warning Label Definitions (For Wordless Labels)

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3-2. Manufacturer’s Rating Labels

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3-3. Symbols And Definitions

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SECTION 4

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SPECIFICATIONS

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4-1. Weld, Power, And Engine Specifications

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4-2. Dimensions, Weights, And Operating Angles

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4-3. Volt-Ampere Curves For CC Models

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4-4. Volt-Ampere Curves For CC/CV Models

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4-5. Fuel Consumption

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4-6. Duty Cycle And Overheating

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4-7. AC Generator Power Curve

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4-8. Optional Three-Phase Generator Curves

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SECTION 5

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INSTALLATION

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5-1. Installing Welding Generator

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5-2. Using Lifting Eye

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5-3. Mounting Welding Generator

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5-4. Installing Exhaust Pipe

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5-5. Activating The Dry Charge Battery (If Applicable)

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5-6. Connecting The Battery

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5-7. Engine Prestart Checks

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5-8. Connecting To Weld Output Terminals

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5-9. Selecting Weld Cable Sizes*

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5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models

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5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models

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SECTION 6

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OPERATING WELDING GENERATOR

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CC MODELS

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6-1. Front Panel Controls For CC Models (See Section 6-2)

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6-2. Description Of Front Panel Controls For CC Models (See Section 6-1)

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6-3. Remote Amperage Control On CC Models (Optional)

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6-4. Weld Control/Arc Condition Information Label

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Summary of Contents for Big Blue 500 PT

Page 1: ...ng MIG GMAW Welding Engine Driven Welding Generator OM 4429 2216 138H 2007 05 Visit our website at www MillerWelds com Flux Cored FCAW Welding Air Carbon Arc CAC A Cutting and Gouging File Engine Driv...

Page 2: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...4 SPECIFICATIONS 15 4 1 Weld Power And Engine Specifications 15 4 2 Dimensions Weights And Operating Angles 15 4 3 Volt Ampere Curves For CC Models 16 4 4 Volt Ampere Curves For CC CV Models 17 4 5 F...

Page 4: ...se Generator CC CV Models Only 39 8 3 Optional Generator Power Receptacles 40 SECTION 9 MAINTENANCE TROUBLESHOOTING 41 9 1 Maintenance Label 41 9 2 Routine Maintenance 42 9 3 Servicing Air Cleaner 43...

Page 5: ...risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC man...

Page 6: ...ing can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire o...

Page 7: ...s bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can...

Page 8: ...ge and frequency caused by low engine speed damage electric motors Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury Wear a face shield t...

Page 9: ...tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Assoc...

Page 10: ...l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structure...

Page 11: ...Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les t...

Page 12: ...r les batteries D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion Arr ter le moteur avant de v rifier le niveau...

Page 13: ...e changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion Ne p...

Page 14: ...INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil N utiliser que les pi ces de rechange recom mand es par le constructeur Effectuer la maintenance et le s...

Page 15: ...onal Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standa...

Page 16: ...tank Leave room for expansion 4 Warning Watch Out There are possible hazards as shown by the symbols Read Owner s Manual Follow instructions to activate battery 5 Check oil level Add oil if necessary...

Page 17: ...OM 4429 Page 13 3 2 Manufacturer s Rating Labels CC Models CC CV Models...

Page 18: ...cal Remote Engine Air Temperature Or Engine Temperature Output Alternating Current Stick SMAW Welding Constant Current CC MIG GMAW Welding TIG GTAW Time h Hours s Seconds 1 Single Phase 3 Three Phase...

Page 19: ...ed Four Cylinder 47 HP Turbocharged Diesel Engine 25 gal 95 L 4 2 Dimensions Weights And Operating Angles Dimensions Height 60 in 1524 mm to top of muffler Width 28 1 2 in 724 mm mtg brackets turned i...

Page 20: ...rage output capabilities of the welding generator Curves of all other settings fall between the curves shown 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 DC AMPERES DC VOLTS Ranges 300 Max...

Page 21: ...ves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 DC AMPERES DC VOLTS Ranges 275 Max 150 525 110 390 80...

Page 22: ...AL HR 0 0 25 0 50 0 75 1 00 1 25 1 50 1 75 2 00 2 25 2 50 0 50 100 150 200 250 300 350 400 450 500 550 600 Continuous Welding 4 6 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes tha...

Page 23: ...MODE 4 8 Optional Three Phase Generator Curves 197 472 197 473 The ac power curves show the gen erator power available in amperes at the single phase 120 240 volt re ceptacle or three phase 240 volt t...

Page 24: ...ion 5 3 for mounting in formation Grounding 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal veh...

Page 25: ...n place Lower lifting eye when not needed To lock the lifting eye in the upright position insert a 3 8 16 x 1 1 2 in carriage bolt through slot in bracket and secure with nut bolt and nut not supplied...

Page 26: ...Supports 2 Mounting Brackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 8 16 x 1 i...

Page 27: ...Needed Ref 803 604 Ref 215 158 Stop engine and let cool Point exhaust pipe in desired di rection but always away from front panel and direction of travel Notes Work like a Pro Pros weld and cut safel...

Page 28: ...If necessary add electro lyte to raise to proper level Reins tall vent caps 8 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 ampere...

Page 29: ...l see maintenance label Coolant Check coolant level in radiator before start ing unit the first time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check coolant...

Page 30: ...ive Weld Output Terminal Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cabl...

Page 31: ...ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 2 ea 4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0...

Page 32: ...ommon distance remote includes 120 V receptacle OUTPUT CONTROL E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust control at max OR 115 VOLTS AC I 1...

Page 33: ...OM 4429 Page 29 Notes...

Page 34: ...OM 4429 Page 30 SECTION 6 OPERATING WELDING GENERATOR CC MODELS 6 1 Front Panel Controls For CC Models See Section 6 2 12 215 663 803 602 11 2 1 8 13 14 9 7 6 4 5 3 10...

Page 35: ...st control adjusts amperage only when welding and does not adjust open circuit voltage The max OCV circuit is disabled when the Stick TIG Selection switch is in Scratch Start TIG position see item 10...

Page 36: ...age Control Stick Adjust Optional Remote Control Set Switches Set Range Set Control Ref 154 862 A Ref 181 711 A 803 602 Max 240 A DC Min 84 A DC 1 In Example Range 115 to 330 A DC Percentage Of Range...

Page 37: ...OM 4429 Page 33 Notes...

Page 38: ...OM 4429 Page 34 SECTION 7 OPERATING WELDING GENERATOR CC CV MODELS 7 1 Front Panel Controls For CC CV Models See Section 7 2 215 664 802 602 13 OR 12 2 1 9 14 15 10 7 6 4 5 8 3 11...

Page 39: ...welding Read the upper set of numbers at each range for Stick welding and the lower set at each range for TIG welding Use the highest range for MIG welding and for cutting and gouging CAC A For most...

Page 40: ...t arc length conditions to prevent stick ing electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG positions Place switch in Weld Terminals Al ways On Stick position when us in...

Page 41: ...ch Set Range Control Not Used In Remote Stick Mode Set Remote Process Example Combination Remote Amperage Control TIG Adjust Optional Remote Control Set V A Adjust Switch Set Range Set Control Set Rem...

Page 42: ...button to verify GFCI is working properly 3 Supplementary Protector CB1 4 Supplementary Protector CB2 CB1 protects RC1 and the genera tor winding from overload If CB1 opens RC1 and GFCI1 do not work P...

Page 43: ...cuit Grounding Lead 7 Lead 90 Neutral 8 Isolated Neutral Terminal 9 Jumper Lead 42 10 Grounding Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neutral to mee...

Page 44: ...st button to verify GFCI is working properly 5 Supplementary Protector CB2 6 Supplementary Protector CB3 CB2 protects GFCI1 from overload If CB2 opens GFCI1 does not work Press button to reset CB3 pro...

Page 45: ...OM 4429 Page 41 SECTION 9 MAINTENANCE TROUBLESHOOTING 9 1 Maintenance Label...

Page 46: ...Section 5 7 9 6 Fuel Water Separator Fuel Level Oil Level Oil Fuel Spills Coolant Level Every 50 Hours Weld Terminals Every 100 Hours Section 9 3 Battery Terminals Air Cleaner Hoses Air Cleaner Eleme...

Page 47: ...fety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element year...

Page 48: ...ow out cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fireproof material Stop engine and let cool Reinstall cleanout plug Tools Needed 3 8 in 1 2 9 5 Checking Genera...

Page 49: ...lows To replace primary fuel filter Turn filter counterclockwise Re move filter Fill new filter with fresh fuel Apply thin coat of fuel to gasket on new fil ter Install new filter and turn clock wise...

Page 50: ...corrected CB5 protects the 24 volt ac output to re mote receptacle RC14 and 24 volt output to field current regulator board PC1 CC CV models only If CB5 opens weld out put and 24 volt output to RC14...

Page 51: ...ive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine sp...

Page 52: ...tored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Check position of Ampere Range switch and Voltage Amperage...

Page 53: ...t resistor R3 Low output at generator power ac receptacles Check engine speed and have Factory Authorized Service Agent adjust if necessary Check fuse F1 and replace if open see Section 9 7 Have Facto...

Page 54: ...d Service Agent check starting aid switch and glow plugs Engine suddenly stops Check oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant temperatureis t...

Page 55: ...OM 4429 Page 51 Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now...

Page 56: ...OM 4429 Page 52 SECTION 10 ELECTRICAL DIAGRAMS Figure 10 1 Circuit Diagram For CC Welding Generator...

Page 57: ...OM 4429 Page 53 223 525 B...

Page 58: ...OM 4429 Page 54 Figure 10 2 Circuit Diagram For CC CV Welding Generator...

Page 59: ...OM 4429 Page 55 223 524 B...

Page 60: ...gs seat faster if engine runs at weld power rpm and the welding generator is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during...

Page 61: ...t of generator see name plate rating label or the specifi cations section in this manual Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator i...

Page 62: ...voltage and current of the generator see nameplate rating label or the specifications section in this manual Check generator and meters after first five minutes then every fifteen minutes to be sure g...

Page 63: ...ctric shock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Groun...

Page 64: ...load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when r...

Page 65: ...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 M...

Page 66: ...P 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 3...

Page 67: ...must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volt...

Page 68: ...to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install...

Page 69: ...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 GFC...

Page 70: ...ilable unless listed 1 2 3 4 5 7 6 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 101 102 103 104 105 100 106 107 108 CC 109 CC 110 111 Fig 13 2 112 113 114 Fig 13 7 115 CV 116 CV 117 118 119 120...

Page 71: ...28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 88 Fig 13 6 89 90 91 92 87...

Page 72: ...046 Hose Air Cleaner 1 010 863 Clamp Hose 1 125 3 000 Clp Dia 4 19 220 091 Hose Sae 500 Id X 750 Od X 13 000 1 20 189 764 Air Cleaner Intake 1 192 938 Filter Air Element Primary 1 192 939 Filter Air E...

Page 73: ...ss 1 53 202 639 Cover Battery Access Ss 1 54 201 006 Bolt J Stl 312 18 X 8 500 Pld 2 55 225 120 Label Warning Moving Parts Can Cause Injury 2 56 215 006 Guard Fan 1 57 197 496 Hose Radiator Lower 1 19...

Page 74: ...Tank Fuel 1 98 189 908 Valve Drain Fuel 180deg 1 99 191 446 Extrusion Rubber W Adhesive 1 000 X 1 000 D Order By Ft 6ft 100 218 086 Bracket Hold Down Fuel Tank 1 101 196 220 Bracket Hold Down Fuel Tan...

Page 75: ...216 135 Kit Label Includes Safety Informational Labels CC CV Models 1 216 993 Kit Label Includes Safety Informational Labels CC Export Models 1 216 992 Kit Label Includes Safety Informational Labels C...

Page 76: ...OM 4429 Page 72 803 845 D 2 1 23 5 4 3 6 20 18 21 16 15 17 8 11 7 12 19 13 9 10 14 22 Figure 13 2 Control Box Assembly CC Models...

Page 77: ...c spst 30a 15vdc 5pin flange mtg 1 12 D10 C10 189 701 DIODE CAPACITOR BOARD 1 13 CB10 190 374 CIRCUIT BREAKER Auto Reset 12vdc 40 Amp 1 14 201 079 COVER control box 1 15 CR5 223 710 RELAY Encl 12vdc D...

Page 78: ...ge mtg 1 6 CR1 090 104 RELAY encl 12vdc spst 30a 15vdc 5pin flange mtg 1 7 Engine Controller 219 848 MODULE control governor 1 LE3 204 702 CORE torodial 187 id x 375 od x 125 thk 1 8 CR6 090104 RELAY...

Page 79: ...pacitor 1 375dia 1 20 D1 C1 189 701 DIODE CAPACITOR BOARD 1 21 TD1 214 928 TIMER delay on make break open 30 sec 12vdc 1 22 CB11 12 13 139 266 SUPPLEMENTARY PROTECTOR man reset 1P 15A 250VAC 3 Optiona...

Page 80: ...34 33 35 36 37 38 39 40 41 42 17 Figure 13 4 Panel Front w Components CC Models Description Part No Dia Mkgs Item No Figure 13 4 Panel Front w Components CC Models Figure 13 1 Item 121 Quantity 1 215...

Page 81: ...do not switch while welding 1 21 S12 195 825 SWITCH polarity 1 22 201 125 PANEL mtg terminal pwr output 1 22 199 303 PANEL mtg terminal pwr output ss 1 23 039 046 TERMINAL pwr output black 1 180 735 W...

Page 82: ...tem the nameplate should also be ordered 1 2 NAMEPLATE screened order by model and serial number 1 3 215 014 PANEL engine weld control 1 3 220544 PANEL engine weld control ss 1 4 S3 208278 SWITCH rang...

Page 83: ...9h brs 3 29 209 056 COVER receptacle w gasket 1 30 083 030 STUD brs 250 20 x 1 750 w hex collar 1 CT2 197 433 TRANSFORMER current sensing 1 31 190 861 LABEL warning electric shock and moving parts etc...

Page 84: ...04 291 A Hardware is common and not available unless listed 24 23 19 14 13 12 16 15 11 18 17 20 35 30 22 28 10 3 4 37 36 27 26 7 2 1 34 33 32 31 29 25 9 8 6 5 21 Figure 13 6 Generator Description Part...

Page 85: ...8 Pln 4 25 191 579 COVER starter hole Continental 2 195 560 GUARD starter hole deutz 912 1 26 083 883 WASHER Lock 402idx0 709odx 087t Stl Split10mm 6 27 172 555 SCREW M10 1 5 x 50hexhd pln 8 8pld 6 28...

Page 86: ...ectifier AC 1 2 188 517 BUS BAR connection board 3 3 188 135 ENCLOSURE rectifier 2 4 134 201 STAND OFF support 3 5 PC3 215 755 CIRCUIT CARD ASSEMBLY protection 1 6 188 136 INSULATOR heat sink 8 7 188...

Page 87: ...Harness Range Switch Includes 1 RC6 148439 Conn Rect Univ 084 4p S 1row Rcpt Cable Panel Lkg Service Kit 1 190259 Harness Wrg Brushholder Includes 1 PLG1 168071 Conn Rect Univ 084 9p S 3row Plug Cable...

Page 88: ...4 Switch Rotary 6 Posn Gold Contacts 1 021467 Switch Tgl Spst 3a 250v Off none On Spd Term 1 S5 011609 Switch Tgl Spdt 15a 125vac On none on Spd Term Chr 1 D1 C1 189701 Diode Capacitor Board 1 193183...

Page 89: ...nduction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers...

Page 90: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal...

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Summary of Contents for Big Blue 500 PT

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Miller Electric Big Blue 500 PT, Owner'S Manual

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Summary of Contents for Big Blue 500 PT

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