Miller Big Blue 500X CE Owner'S Manual Download Page 35 | Manualshive

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Complete Parts List available at www.MillerWelds.com

OM-271 838 Page 29

SECTION 6

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OPERATING WELDER/GENERATOR

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

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Summary of Contents for Big Blue 500X CE

Page 1: ...n TIG GTAW Welding Stick SMAW Welding Engine Driven Welder Generator OM 271 838B 2015 05 Visit our website at www MillerWelds com Air Carbon Arc CAC A Cutting and Gouging File Engine Drive Big Blue 500X CE Perkins Powered ...

Page 2: ...ontinue 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 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 worksite We ve made installation and operati...

Page 3: ...SECTION 4 SPECIFICATIONS 19 4 1 Serial Number And Rating Label Location 19 4 2 Weld Power And Engine Specifications 19 4 3 Dimensions Weights And Operating Angles 19 4 4 Environmental Specifications 19 4 5 Duty Cycle And Overheating 20 4 6 Volt Ampere Curves 21 4 7 Fuel Consumption 21 4 8 AC Generator Power Curve 22 SECTION 5 INSTALLATION 23 5 1 Installing Welder Generator 23 5 2 Grounding Generat...

Page 4: ...ntenance 39 8 7 Engine Speed Adjustment 39 8 8 Servicing Fuel And Lubrication Systems 40 8 9 Overload Protection 41 8 10 Troubleshooting 42 SECTION 9 PARTS LIST 44 9 1 Recommended Spare Parts 44 SECTION 10 ELECTRICAL DIAGRAMS 46 SECTION 11 RUN IN PROCEDURE 48 11 1 Wetstacking 48 11 2 Run In Procedure Using Load Bank Or Resistance Grid 49 SECTION 12 GENERATOR POWER GUIDELINES 50 COMPLETE PARTS LIST...

Page 5: ...trical and electronic equipment 2000 14 EC 2005 88 EC Outdoor Noise Notified Body AV Technology AVTECH House Arkle Avenue Stanley Green Trading Estate Hand forth Cheshire SK93RW United Kingdom Conformity Assessment Procedure Followed Annex VI 2000 14 EC Technical Document Holder Manufacturer Notified Body Evaluation Report No 002 Measured Sound Power level 97 dB L WA Guaranteed Sound Power Level 9...

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Page 7: ...high 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 manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or sto...

Page 8: ...ing sparks and hot materials from welding 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 on the hidden side Do not weld on containers that have held combustibles or on closed containers such as tanks drums or pipes unless they are properly prepared acc...

Page 9: ...le hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can burn If possible check coolant level when engine is cold to avoid scalding Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual If the engine is warm checking is needed and there ...

Page 10: ...T PARTS can burn Do not touch hot compressor or air system parts 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 READ INSTRUCTIONS Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the...

Page 11: ...g wire OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards TILTING OF TRAILER can injure Use tongue jack or b...

Page 12: ...or Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupat...

Page 13: ...quipé Des précautions de sécurité supplémentaires sont requises dans des environnements à risque comme les endroits humides ou lorsque l on porte des vêtements mouillés sur des structures mé talliques au sol grillages et échafaudages dans des positions assises à genoux et allongées ou quand il y a un risque important de contact accidentel avec la pièce ou le sol Dans ces cas utiliser les appareils...

Page 14: ... des blessures ou même la mort Fermer l alimentation du gaz comprimé en cas de non utilisation Veiller toujours à bien aérer les espaces confinés ou se servir d un respirateur d adduction d air homologué LES RAYONS DE L ARC peuvent provoquer des brûlures dans les yeux et sur la peau Le rayonnement de l arc du procédé de soudage génère des rayons visibles et invisibles intenses ultraviolets et infr...

Page 15: ...rs de l ouverture de la vanne de la bouteille Ne pas se tenir devant ou derrière le régulateur lors de l ouverture de la vanne Maintenir le chapeau de protection sur la soupape sauf en cas d utilisationou de branchement de la bouteille Utiliser les équipements corrects les bonnes procédures et suffi samment de personnes pour soulever et déplacer les bouteilles Lire et suivre les instructions sur l...

Page 16: ... 2 4 Dangers liés à l air comprimé Un ÉQUIPEMENT PNEUMATIQUE risque de provoquer des blessures ou même la mort Une installation ou une utilisation incorrecte de cet appareil pourrait conduire à des dégâts matériels ou corporels Seul un personnel qualifié est autorisé à installer utiliser et entretenir cet appareil conformément à son manuel d utilisation aux normes industrielles et aux codes nation...

Page 17: ...ilisation ou l entretien de l appareil Lire les informations de sécurité au début du manuel et dans chaque section N utiliser que les pièces de rechange recommandées par le constructeur Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d état et locaux 2 5 Dangers supplémentaires en relation avec l installation le fonctionnement et la mai...

Page 18: ...dage L EMPLOI EXCESSIF peut SURCHAUFFER L ÉQUIPEMENT Laisser l équipement refroidir respecter le fac teur de marche nominal Réduire le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste LES CHARGES ÉLECTROSTATI QUES peuvent endommager les circuits imprimés Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des piè...

Page 19: ... Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot...

Page 20: ...OM 271 838 Page 14 ...

Page 21: ... Protect yourself from electric shock by insulating yourself from work and ground Safe3 2012 05 Keep your head out of the fumes Safe6 2012 05 Use forced ventilation or local exhaust to remove the fumes Safe8 2012 05 Use ventilating fan to remove fumes Safe10 2012 05 Keep flammables away from welding Do not weld near flammables Safe12 2012 05 Welding sparks can cause fires Have a fire extinguisher ...

Page 22: ...esignated collection facility Contact your local recycling office or your local distributor for further information Safe37 2012 05 Do not use ether or other starting fluids Using starting fluids voids warranty See engine Owner s Manual Safe89 2015 02 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection ...

Page 23: ...oil and filter Never use generator inside a home or garage even if doors and win dows are open Safe87 2012 07 Only use generator outside and far away from windows doors and vents Safe88 2012 07 3 2 Miscellaneous Symbols And Definitions Some symbols are found only on export products Read Operator s Manual Clock Time Switch A Amperage V Voltage Hz Hertz Seconds h Hours U0 Rated No Load Voltage OCV U...

Page 24: ...ased Risk Of Electric Shock Off On Increase De crease of Quantity Rotating Number of Positions Panel Local Remote Contractor On Do Not Switch While Welding Welding General Shielded Metal Arc Welding SMAW Gas Tungsten Arc Welding GTAW Tungsten Inert Gas TIG Welding Constant Current Electrode Connection Work Connection Engine Oil Engine Oil Pressure Fuel Battery Engine Engine Engine Engine RPM Engin...

Page 25: ...nsions Weights And Operating Angles Dimensions D B A F E H G C 20 20 30 30 Do not exceed tilt angles or engine could be damaged or unit could tip Do not move or operate unit where it could tip 802 161 A 803 656 G Height 60 in 1524 mm to top of muffler Width 28 1 2 in 724 mm mtg brackets turned in 30 3 4 in 781 mm mtg brackets turned out Depth 65 1 8 in 1654 mm A 65 1 8 in 1654 mm B 56 in 1422 mm C...

Page 26: ...components of the welding circuit for additional EMF exposure information The EMF assessment on this equipment was conducted at 0 5 meter At a distance of 1 meter the EMF exposure values were less than 20 of the permissible values ce emf 1 2010 10 C Information On Electromagnetic Compatibility EMC This Class A equipment is not intended for use in residential locations where the electrical power is...

Page 27: ...s shown A Stick Mode B TIG Mode DC VOLTS DC AMPERES 100 80 60 40 20 0 0 100 200 300 400 500 RANGES 60 365 35 250 25 155 15 75 0 100 200 300 400 500 600 700 800 900 1000 100 80 60 40 20 0 DC VOLTS DC AMPERES RANGES 230 MAX 170 365 110 225 70 130 55 85 4 7 Fuel Consumption The curve shows typical fuel use under weld or power loads 199 032 A DC WELD AMPERES AT 100 DUTY CYCLE US Gal Hr 0 50 100 150 20...

Page 28: ...rve shows the gen erator power in amperes available at the 120 and 240 volt receptacles 0 50 100 150 200 250 300 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE AC VOLTS 0 25 50 75 100 150 125 0 10 20 30 40 50 60 AC AMPERES IN 120V MODE 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 29: ...ehicle or trailer and comply with all DOT and other applicable codes Do not weld on base Welding on base can cause fuel tank fire or ex plosion Weld only on the four mounting brackets or bolt unit down NOTICE Do not mount unit by supporting the base only at the four mounting brack ets Use cross supports to adequately support unit and prevent damage to base 1 Cross Supports 2 Mounting Brackets Supp...

Page 30: ... when operating auxiliary equip ment If unit does not have GFCI receptacles use GFCI protected extension cord Do not use GFCI receptacles to power life support equip ment 1 EquipmentGrounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 8 AWG or larger insu lated copper wire Electrically bond ge...

Page 31: ...ICE Wait two minutes after engine shutdown before disconnecting battery or engine controller may be damaged Battery is most easily accessed through the rear panel Remove battery access panel from rear panel Connect battery negative cable last Reinstall battery ac cess panel Do not allow the battery cables to touch opposing terminals When con necting the battery cables attach the positive cable to ...

Page 32: ...Coolant Check coolant level in radiator before start ing unit the first time If necessary add coolant to radiator until coolant level is at bottom of filler neck Check coolant level in recovery tank daily If necessary add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels If recovery tank coolant level was low also check coolant level in radiator Add coolant if l...

Page 33: ...d Cable Connection 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remove supplied nut from weld output termi nal Slide weld cable terminal onto weld output terminaland secure with nut so that weld cable terminal is tight against copper bar 7 Positive Weld Output Terminal 8 Negative Weld Output Terminal Stick and TIG Welding For Stick and TIG welding D...

Page 34: ...0 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 2x4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 2x4 0 2x120 500 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 3x3 0 3x95 3x3 0 3x95 600 3 0 95 4 0 120 2x2 ...

Page 35: ... Complete Parts List available at www MillerWelds com OM 271 838 Page 29 SECTION 6 OPERATING WELDER GENERATOR 6 1 Front Panel Controls See Section 6 2 12 240 162 803 656 11 2 1 8 9 7 6 4 5 3 10 13 ...

Page 36: ...e Amperage Adjust 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 8 6 Ampere Range Switch NOTICE Do not switch under load Use switch to select weld amperage range For most welding applications use lowest amperagerange possible to help prevent arc outages...

Page 37: ...mbination Remote Amperage Control Stick Adjust Optional Remote Control Set Switches Set Range Set Control Ref 154 862 A Ref 181 711 A 803 602 In Example Range 110 to 225 A DC Percentage Of Range 50 Max About 168 A DC 50 of 110 to 225 Max 168 A DC Min 90 A DC 1 6 4 Weld Control Arc Condition Information Label Set weld controls as shown to achieve softer or stiffer arc condi tions for different appl...

Page 38: ... Complete Parts List available at www MillerWelds com Complete Parts List available at www MillerWelds com OM 271 838 Page 32 6 5 Fuel Hour Gauge Descriptions ...

Page 39: ...ut of all recep tacles is 4 kVA kW EXAMPLE If 13 A is drawn from RC1 only 7 A is available at GFCI1 240 V x 13 A 120 V x 7 A 4 0 kVA kW 2 Circuit Breaker CB2 CB2 protects GFCI1 from overload If a cir cuit breaker opens the receptacle does not work Press CB2 to reset breaker 3 Earth Leakage Circuit Breaker ELCB1 ELCB1 protects RC1 from Earth leakage fault If circuit breaker opens the receptacle doe...

Page 40: ...Test GFCI monthly See Testing GFCI Receptacle Do not test or reset GFCI receptacles at idle speed low voltage or the GFCI will be damaged and not provide protection from electric shock caused by a ground fault If LED blinks stop using GFCI re ceptacle and have it replaced by a Factory Authorized Service Agent Extension cords with bad insulation or of extended length can allow enough leakage curren...

Page 41: ...OTING 8 1 Maintenance Label Perkins Engine North American office Perkins USA Canada Office Perkins Engines Inc N4 AC6160 PO Box 610 Mossville Illinois 61552 0610 Toll Free Number 1 888 PERK ENG Telephone 1 309 578 7364 Fax 1 309 578 7329 To find a service distributor go to http www perkins com distributor ...

Page 42: ...rs FUEL WATER Section 5 6 8 8 Fuel Water Separator Fuel Level Oil Level Oil Fuel Spills Coolant Level Every 50 Hours Weld Terminals Every 100 Hours Section 8 4 Battery Terminals Air Cleaner Hoses Air Cleaner Element Every 250 Hours 1 2 in 13 mm Engine Manual Section 8 5 Unreadable Labels Fan Belt Tension Spark Arrestor Every 500 Hours NOTICE Change engine oil and filter after initial 50 to 75 hour...

Page 43: ...nd let cool 1 Generator Brush Mark and disconnect leads at brush hold er cap Remove brushes Replace brushes if damaged or if brush material is at or near minimum length 1 Damaged Brushes New Length 1 1 4 in 32 mm Minimum Length 5 8 in 16 mm Replace Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 44: ...Replace the safety element after servicing the pri mary element three times 1 Intake Manifold 2 Service Indicator Optional 3 Window 4 Reset Button Service air cleaner element if red band appears in window A green band means air cleaner is okay Press button to reset indicator Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primar...

Page 45: ...eeded 3 8 in 1 2 8 6 Battery Maintenance Lead acid batteries discharge when stored in any temperature Units that are stored should have the battery recharged every three months and before being put into service To preserve optimum battery performance and life recharge battery in storage when the open circuit voltage drops to 12 4 volts DC when measured across the battery terminals 8 7 Engine Speed...

Page 46: ...etal container Close petcock when water free fuel flows 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 Bleed air from fuel system ac cording to engine manual Inspect fuel lines and replace if cracked or worn To replace secondary fuel filter See engine ...

Page 47: ...Breaker CB14 Not Shown CB4 protects the welding arc drive dig circuit If CB4 opens electrode may stick to the workpiece more frequently during low voltage short arc length conditions CB4 automatically resets when the fault is corrected CB10 protects the engine battery circuit If CB10 opens the engine will not crank CB10 automatically resets when the fault is corrected CB11 protects the weld contro...

Page 48: ...e is clean and tight Use dry properly stored 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 Adjust control Check engine speed and have engine manufacturer s factory authorized service agent adjust if neces sary Have Factory Authorized Service Agent chec...

Page 49: ...replace if necessary Check battery connections and tighten if necessary Circuit breaker CB10 may be open CB10 automatically resets when fault is corrected see Section 8 9 Have Factory Authorized Service Agent check engine wiring harness and components Check engine wiring harness plug connections Have Factory Authorized Service Agent check control relay CR1 and Engine Control switch S1 Engine crank...

Page 50: ... Check for obstructed throttle solenoid Engine does not run at idle speed models with idle option only CC models place Stick TIG Selection switch in Stick position CC CV models place Process Contactor switch in any position but Remote On Off Switch Required TIG Check for obstructed throttle solenoid Have Factory Authorized Service Agent check idle module PC7 and control relays CR3 and CR6 Engine u...

Page 51: ... Complete Parts List available at www MillerWelds com OM 271 838 Page 45 Notes ...

Page 52: ...OM 271 838 Page 46 SECTION 10 ELECTRICAL DIAGRAMS Figure 10 1 Circuit Diagram For Welder Generator ...

Page 53: ...OM 270 838 Page 47 240 152 B ...

Page 54: ... age and current during run in period to properly seat piston rings and prevent wetstacking See name plate rating label or specifications section in this manual to find rated voltage and current NOTICE Do not idle engine longer than necessary Piston rings only seat correctly if engine runs at weld power rpm and the welder genera tor is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is...

Page 55: ...own if not provided on generator Start engine and run for several minutes For Load Bank Set load bank switches and then adjust generator A V control so load equals rated voltage and current of generator see nameplate rating label or the specificationssection in this manual For Resistance Grid Set grid switches and then adjust gen erator A V control so load equals rated voltage and current of the g...

Page 56: ...Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Gen erators 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 8 AWG or larger insulated copper wire Electrically bond generator frame to ve hicle frame by metal to metal contact Bed liners shipping skids a...

Page 57: ...ve 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 running see Section 12 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run ni...

Page 58: ...m 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 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 ...

Page 59: ...1 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 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 GPH 600 200 Centrifugal Pump 900 GPH 900 500...

Page 60: ... 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 Volts 230 HP 1 4 kVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes VOLTS AMPS HP 230 2 5 1 4 Hz PHASE CODE 60 1 M AC MOTOR 1 2 3 4 12 9 How Much Power Can Generator Supply ...

Page 61: ...oad back 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 correct switch customer supplied if required by electrical code 4 Welder GeneratorOutput Generator output voltage and wir ing must be consistent with regular utility system voltage and wirin...

Page 62: ...50 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 Use GFCI protection when operating auxiliary equipment Do not use GFCI receptacles to power life support equipment Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Amperes Load Watts 4 6 8 10 12 14 5 1200 700 213 450 137 225...

Page 63: ...uns and Subarc SAW Torches Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine d...

Page 64: ...h 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 Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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