Table of Contents
Troubleshooting
Related Manuals for Miller Big Blue 500X CE
Summary of Contents for Miller Big Blue 500X CE
- Page 1 OM-271 838B 2015−05 Processes Stick (SMAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welder/Generator Big Blue 500X (Perkins-Powered) File: Engine Drive Visit our website at www.MillerWelds.com...
- Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ....... . . 1-1. - Page 4 TABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING ......... 8-1.
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Page 5: Declaration Of Conformity
DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914, U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s). -
Page 7: Section 1 − Safety Precautions − Read Before Using
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2015−04 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. - Page 8 D Be alert that welding sparks and hot materials from welding can FLYING METAL or DIRT can injure easily go through small cracks and openings to adjacent areas. eyes. D Watch for fire, and keep a fire extinguisher nearby. D Welding, chipping, wire brushing, and grinding D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause sparks and flying metal.
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Page 9: Engine Hazards
1-3. Engine Hazards EXHAUST SPARKS can cause fire. BATTERY EXPLOSION can injure. D Do not let engine exhaust sparks cause fire. D Always wear a face shield, rubber gloves, and D Use approved engine exhaust spark arrestor in protective clothing when working on a battery. required areas —... -
Page 10: Additional Symbols For Installation, Operation, And Maintenance
HOT METAL from air arc cutting and MOVING PARTS can injure. gouging can cause fire or explosion. D Keep away from moving parts such as fans, D Do not cut or gouge near flammables. belts and rotors. D Watch for fire; keep extinguisher nearby. D Keep all doors, panels, covers, and guards closed and securely in place. - Page 11 BATTERY CHARGING OUTPUT and BATTERY STATIC (ESD) can damage PC boards. EXPLOSION can injure. D Put on grounded wrist strap BEFORE handling Battery charging not present on all models. boards or parts. D Use proper static-proof bags and boxes to D Always wear a face shield, rubber gloves, and store, move, or ship PC boards.
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Page 12: California Proposition 65 Warnings
1-6. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &... -
Page 13: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2015−04 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. - Page 14 D Utiliser une protection différentielle lors de l’utilisation d’un équi- LES ACCUMULATIONS DE GAZ pement auxiliaire. Ne pas tester ni réarmer les prises femelles risquent de provoquer des blessures avec différentiel au régime de ralenti/en basse tension: cela ou même la mort. endommagerait le disjoncteur différentiel, qui ne remplirait plus son rôle de protection contre une électrocution causée par un D Fermer l’alimentation du gaz comprimé...
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Page 15: Dangers Existant En Relation Avec Le Moteur
D Porter un équipement de protection pour le corps fait d’un matériau Si des BOUTEILLES sont endomma- résistant et ignifuge (cuir, coton robuste, laine). La protection du gées, elles pourront exploser. corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette. -
Page 16: Dangers Liés À L'air Comprimé
D Pour empêcher tout démarrage accidentel pendant les travaux D Toujours vérifier le niveau de liquide de refroidissement dans le d’entretien, débrancher le câble négatif (−) de batterie de la borne. vase d’expansion (si présent), et non dans le radiateur (sauf si pré- cisé... -
Page 17: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
D Pour rechercher des fuites, utiliser de l’eau savonneuse ou D Ne pas approcher les mains, cheveux, vêtements lâches et outils un détecteur à ultrasons, jamais les mains nues. En cas des organes mobiles. de détection de fuite, ne pas utiliser l’équipement. D Avant d’intervenir sur le circuit d’air comprimé, couper D Remettre les portes, panneaux, recouvrements ou dispositifs l’alimentation électrique, verrouiller et étiqueter l’appareil,... - Page 18 LA SORTIE DE RECHARGE et L’EXP- LES CHARGES ÉLECTROSTATI- LOSION DE LA BATTERIE peuvent QUES peuvent endommager les provoquer des blessures. circuits imprimés. La recharge de batterie n’existe pas sur tous les D Établir la connexion avec la barrette de terre modèles.
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Page 19: Proposition Californienne 65 Avertissements
2-6. Proposition californienne 65 Avertissements Pour les moteurs à essence : Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques Les gaz d’échappement des moteurs contiennent des pro- dont l’État de Californie reconnaît qu’ils provoquent des mal- duits chimiques dont l’État de Californie reconnaît qu’ils formations congénitales et, dans certains cas, des cancers. - Page 20 OM-271 838 Page 14...
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Page 21: Section 3 − Definitions
Complete Parts List available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012−05 Protect yourself from electric shock by insulating yourself from work and ground. - Page 22 Complete Parts List available at www.MillerWelds.com Complete Parts List available at www.MillerWelds.com Do not work on unit if engine is running. Stop engine first. Safe21 2012−05 Do not smoke while fueling or if near fuel. Safe22 2012−05 Stop engine before fueling. Safe23 2012−05 Do not fuel a hot engine.
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Page 23: Miscellaneous Symbols And Definitions
Complete Parts List available at www.MillerWelds.com Read Owner’s Manual. Read labels on unit. Safe47 2012−05 <12.4 V Read Owner’s Manual for battery maintenance information. Safe117 2014−06 + − + − 0 - 50 h std During the first 50 hours of operation keep welding load above 200 amperes. - Page 24 Complete Parts List available at www.MillerWelds.com Complete Parts List available at www.MillerWelds.com Direct Current Contractor On Engine (DC) Do Not Switch Protective Earth Engine While Welding (Ground) Circuit Breaker Welding (General) Engine RPM Supplementary Protector Shielded Metal Engine Stop Arc Welding Single Phase (SMAW) Gas Tungsten Arc...
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Page 25: Section 4 − Specifications
Complete Parts List available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated output. -
Page 26: Duty Cycle And Overheating
Complete Parts List available at www.MillerWelds.com Complete Parts List available at www.MillerWelds.com B. Information On Electromagnetic Fields (EMF) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person. -
Page 27: Volt-Ampere Curves
Complete Parts List available at www.MillerWelds.com 4-6. Volt-Ampere Curves A. Stick Mode The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of RANGES: the welder/generator. Curves of all other settings fall between the 230 − MAX curves shown. -
Page 28: Ac Generator Power Curve
Complete Parts List available at www.MillerWelds.com Complete Parts List available at www.MillerWelds.com 4-8. AC Generator Power Curve The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. AC AMPERES IN 240V MODE AC AMPERES IN 120V MODE 193 018 Notes... -
Page 29: Section 5 − Installation
Complete Parts List available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Installing Welder/Generator Airflow Clearance 18 in. Movement (460 mm) 18 in. (460 mm) 18 in. (460 mm) 18 in. 18 in. (460 mm) (460 mm) Location/Mounting Bolting Welding Unit In Unit In Place Place... -
Page 30: Grounding Generator To Truck Or Trailer Frame
Complete Parts List available at www.MillerWelds.com Complete Parts List available at www.MillerWelds.com 5-2. Grounding Generator To Truck Or Trailer Frame Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. Also see AWS Safety & Health Fact Sheet No. -
Page 31: Installing Exhaust Pipe
Complete Parts List available at www.MillerWelds.com 5-4. Installing Exhaust Pipe Stop engine and let cool. Position exhaust pipe with spark arrestor as shown in illustration. Follow spark arrestor kit installa- tion instructions. Tools Needed: 1/2 in Exhaust4 2015−03 Ref. 803 604 / Ref. 215 664 / Ref. 907 602−1 5-5. -
Page 32: Engine Prestart Checks
Use Starting Aid switch (see Section ing unit the first time. If necessary, add NOTICE − Diesel engines in Miller equip- 6-1). coolant to radiator until coolant level is at ment are meant to operate optimally at mod- bottom of filler neck. -
Page 33: Connecting To Weld Output Terminals
Complete Parts List available at www.MillerWelds.com 5-7. Connecting To Weld Output Terminals Stick and TIG Welding For Stick and TIG welding Direct Current Elec- trode Positive (DCEP), connect electrode holder cable to Positive (+) terminal on left and work cable to Negative (−) terminal on right. For Direct Current Electrode Negative (DCEN), reverse cable connections. -
Page 34: Selecting Cable Sizes
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-L 2015−02 5-9. Connecting To Remote Amperage Adjust Receptacle RC13... -
Page 35: Section 6 − Operating Welder/Generator
Complete Parts List available at www.MillerWelds.com SECTION 6 − OPERATING WELDER/GENERATOR 6-1. Front Panel Controls (See Section 6-2) 240 162 / 803 656 OM-271 838 Page 29... -
Page 36: Description Of Front Panel Controls (See Section 6-1)
(short arc length conditions) to C). Engine stops if temperature exceeds 220° prevent “sticking” electrodes. NOTICE − Diesel engines in Miller equipment F (104° C). are meant to operate optimally at moderate to When switch is in Scratch Start TIG position, Weld Controls rated load. -
Page 37: Remote Amperage Control (Optional)
Complete Parts List available at www.MillerWelds.com 6-3. Remote Amperage Control (Optional) Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-9). In Example: Example: Combination Remote Amperage Control (Stick) Range = 110 to 225 A DC Percentage Of Range = 50% Max = About 168 A DC (50% of 110 to 225) Max (168 A DC) -
Page 38: Fuel/Hour Gauge Descriptions
Complete Parts List available at www.MillerWelds.com Complete Parts List available at www.MillerWelds.com 6-5. Fuel/Hour Gauge Descriptions OM-271 838 Page 32... -
Page 39: Section 7 − Operating Auxiliary Equipment
Complete Parts List available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Export Auxiliary Power Receptacles European Receptacle Australian Receptacle South African Receptacle 238 127-A / 805 259-A and 4 kVa/kW from RC1. does not work. Place circuit breaker switch Use GFCI protection when operat- in the On position to reset breaker. -
Page 40: Gfci Receptacle Information, Resetting And Testing
Complete Parts List available at www.MillerWelds.com Complete Parts List available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting And Testing Test and reset GFCI only at Run speed. RotGFCI1 2014−09 If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles Use GFCI protection when operating button pops out, and the circuit opens to dis- auxiliary equipment. -
Page 41: Section 8 − Maintenance & Troubleshooting
Complete Parts List available at www.MillerWelds.com SECTION 8 − MAINTENANCE & TROUBLESHOOTING 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:... -
Page 42: Routine Maintenance
Complete Parts List available at www.MillerWelds.com Complete Parts List available at www.MillerWelds.com 8-2. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions. -
Page 43: Checking Generator Brushes
Complete Parts List available at www.MillerWelds.com 8-3. Checking Generator Brushes Stop engine and let cool. Generator Brush Mark and disconnect leads at brush hold- er cap. Remove brushes. Minimum Length: Replace brushes if damaged or if brush 5/8 in. (16 mm) material is at or near minimum length. -
Page 44: Servicing Air Cleaner
Complete Parts List available at www.MillerWelds.com Complete Parts List available at www.MillerWelds.com 8-4. Servicing Air Cleaner Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each... -
Page 45: Inspecting/Cleaning Optional Spark Arrestor
Complete Parts List available at www.MillerWelds.com 8-5. Inspecting/Cleaning Optional Spark Arrestor Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhaust pipe with fireproof material. -
Page 46: Servicing Fuel And Lubrication Systems
Complete Parts List available at www.MillerWelds.com Complete Parts List available at www.MillerWelds.com 8-8. Servicing Fuel And Lubrication Systems Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary, and wipe up spilled fuel. -
Page 47: Overload Protection
Complete Parts List available at www.MillerWelds.com 8-9. Overload Protection Stop engine. When a supplementary protector, circuit breaker or fuse opens, it usu- ally indicates a more serious problem exists. Contact Factory Authorized Service Agent. Fuse F1 Fuse F2 F1 and F2 protect the stator exciter wind- ing from overload. -
Page 48: Troubleshooting
Complete Parts List available at www.MillerWelds.com Complete Parts List available at www.MillerWelds.com 8-10. Troubleshooting A. Welding Trouble Remedy No weld output; generator power output Check position of Ampere Range switch. okay at ac receptacles. Check position of optional Polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote control to Remote Amperage Adjust receptacle RC13 (see Sections 5-9 and 6-1). - Page 49 Complete Parts List available at www.MillerWelds.com Trouble Remedy No remote fine amperage control. Repair or replace remote control device. Have Factory Authorized Service Agent check OCV control circuit. B. Standard Generator Power Trouble Remedy No generator power output at ac recep- Reset receptacle supplementary protectors.
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Page 50: Section 9 − Parts List
Complete Parts List available at www.MillerWelds.com Complete Parts List available at www.MillerWelds.com Trouble Remedy See engine manual. Engine slowly stopped and cannot be Check fuel level. restarted. Check engine air and fuel filters (see Sections 8-4 and 8-8). See engine manual. Battery discharges between uses. - Page 51 Complete Parts List available at www.MillerWelds.com Notes OM-271 838 Page 45...
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Page 52: Section 10 − Electrical Diagrams
SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welder/Generator OM-271 838 Page 46... - Page 53 240 152-B OM-270 838 Page 47...
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Page 54: Section 11 − Run-In Procedure
2014−09 NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary. -
Page 55: Run-In Procedure Using Load Bank Or Resistance Grid
11-2. Run-In Procedure Using Load Bank Or Resistance Grid S-0683 / S-0684 Stop engine. Weld Cables voltage and current of the generator (see nameplate, rating label, or the Resistance Grid Do not touch hot exhaust pipe, en- specifications section in this manual). gine parts, or load bank/grid. -
Page 56: Section 12 − Generator Power Guidelines
SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 12-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment... - Page 57 12-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. GND/PE Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
- Page 58 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
- Page 59 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in. 3/8 in. 1/2 in. Circular Saw 6-1/2 in. 7-1/4 in. 8-1/4 in. 1400 1400 Table Saw 9 in. 4500 1500 10 in. 6300 1800 Band Saw 14 in.
- Page 60 12-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
- Page 61 12-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install, ground, and operate this equipment ac- cording to its Owner’s Manu- al and national, state, and lo- cal codes.
- Page 62 12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 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 Load (Watts) (Amperes)
- Page 63 Effective January 1, 2015 (Equipment with a serial number preface of MF or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
- Page 64 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2015 Miller Electric Mfg. Co. 2015−01...
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