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Miller Electric Big Blue 500D Owner's Manual

Engine driven welding generator
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www.MillerWelds.com
Big Blue 500D
Big Blue 600 X
(Deutz-Powered)
OM-4428
2007−10
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
R
R
File: Engine Drive
215 932K

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Summary of Contents for Miller Electric Big Blue 500D

  • Page 1 Visit our website at www.MillerWelds.com Big Blue 500D Big Blue 600 X (Deutz-Powered) OM-4428 215 932K 2007−10 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 TABLE OF CONTENTS SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 7-3. Process/Contactor Switch On CC/CV Models 7-4.

  • Page 5: Section 1 − Safety Precautions − Read Before Using

    DC 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! D Disconnect input power or stop engine before installing or servicing this equipment.
  • Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

  • Page 7: Engine Hazards

    D Do not allow tools to cause sparks when working on a battery. D Do not use welder to charge batteries or jump start vehicles. D Observe correct polarity (+ and −) on batteries.

  • Page 8: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and gouging can cause fire or explosion. D Do not cut or gouge near flammables. D Watch for fire; keep extinguisher nearby. HOT PARTS can cause burns and injury. D Do not touch hot compressor or air system parts.

  • Page 9: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

  • Page 10: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
  • Page 11 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. D Ne pas toucher à mains nues les parties chau- des. D Prévoir une période de refroidissement avant de travailler à l’équipement. D Ne pas toucher aux pièces chaudes, utiliser les outils recomman- dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.

  • Page 12: Dangers Existant En Relation Avec Le Moteur

    LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux. D Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance. D Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de sou- dage par points, de gougeage, du coupage plasma ou de chauf- fage par induction.

  • Page 13: Dangers Liés À L'air Comprimé

    L’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. D Les fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore. D JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes. D Uniquement utiliser à...
  • Page 14 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. D Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur. D Ne pas laisser tourner le moteur trop lentement sous risque d’en- dommager le moteur électrique à cause d’une tension et d’une fré- quence trop faibles.

  • Page 15: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé...

  • Page 16: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions (For Wordless Labels) 0 − 50 h Std. 50 h Std. Notes OM-4428 Page 12 S-177 571 DIESEL 200A 0 − 200A API CD-MIL L 2104D, CD/SE, CD/SF MATERIAL THICKNESS REFERENCE CHART Remove unit from shipping crate.

  • Page 17: Manufacturer's Rating Labels

    3-2. Manufacturer’s Rating Labels CC Models CC/CV Models OM-4428 Page 13...

  • Page 18: Symbols And Definitions

    3-3. Symbols And Definitions Some symbols are found only on CE products. Stop Engine Starting Aid Check Injectors/ Pump Positive Amperes Engine Stick (SMAW) Welding Time Three Phase Electrode Connection Duty Cycle Rated Idle Speed Contactor On OM-4428 Page 14 Fast (Run, Weld/ Power) Battery (Engine)

  • Page 19: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Weld Welding Rated Welding Output Mode Output Range 65 − 600 A (CC Models) CC/DC 600 A, 30 Volts DC, 20 − 600 A 40% Duty Cycle (CC/CV Models) IFC Rating 500 A, 40 Volts DC, 500 A, 40 Volts DC, 100% Duty Cycle...

  • Page 20: Volt-Ampere Curves For Cc Models

    4-3. Volt-Ampere Curves For CC Models Notes OM-4428 Page 16 Ranges 300−Max 185−425 125−320 85−190 55−90 DC AMPERES 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.

  • Page 21: Volt-Ampere Curves For Cc/Cv Models

    4-4. Volt-Ampere Curves For CC/CV Models A. Stick Mode 200 300 400 DC AMPERES B. MIG Mode 100 200 300 400 500 600 700 800 900 1000 DC AMPERES C. TIG Mode DC AMPERES Ranges 275−Max 150−525 110−390 80−240 50−125 1000 500 600 700 800 900 Ranges...

  • Page 22: Fuel Consumption

    4-5. Fuel Consumption 1800 RPM IDLE DC WELD AMPERES AT 100% DUTY CYCLE Notes OM-4428 Page 18 100 150 200 250 300 350 400 450 500 The curve shows typical fuel use under weld or power loads. 193 093...

  • Page 23: Duty Cycle And Overheating

    4-6. Duty Cycle And Overheating 100% Duty Cycle At 500 Amperes 4-7. AC Generator Power Curve AC AMPERES IN 240V MODE AC AMPERES IN 120V MODE Continuous Welding Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.

  • Page 24: Optional Three-Phase Generator Curves

    4-8. Optional Three-Phase Generator Curves A. 12 kVA/kW Single-Phase AC Output (No Weld Load) B. 20 kVA/kW Three-Phase AC Output (No Weld Load) OM-4428 Page 20 AC AMPERES AC AMPERES 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 terminals.

  • Page 25: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Movement Location/Airflow Clearance 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) (460 mm) Grounding GND/PE 18 in (460 mm) 18 in Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.

  • Page 26: Using Lifting Eye

    5-2. Using Lifting Eye Notes OM-4428 Page 22 Lifting Eye Carriage Bolt Raise lifting eye until it snaps in 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 27: Mounting Welding Generator

    5-3. Mounting Welding Generator Supporting The Unit Using Mounting Brackets Tools Needed: 9/16 in Welding Unit In Place Bolting Unit In Place install3 2007−04 803 274 / 200 864-A /803 602-B Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion.

  • Page 28: Installing Exhaust Pipe

    5-4. Installing Exhaust Pipe Tools Needed: 1/2 in 5-5. Installing Optional Ether Cylinder (Deutz F3L912 Engine Only) OM-4428 Page 24 Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Ref.

  • Page 29: Activating The Dry Charge Battery (If Applicable)

    5-6. Activating The Dry Charge Battery (If Applicable) 5 A For 30 Minutes 30 A For 12 Minutes Tools Needed: 5-7. Connecting The Battery Connect negative (−) cable last. Tools Needed: 1/2 in − − Always wear a face shield, rubber gloves and protective clothing when working on a battery.

  • Page 30: Engine Prestart Checks

    5-8. Engine Prestart Checks Full Diesel Deutz F4L2011 Engine Full Diesel Deutz F3L912 Engine Check all engine fluids daily. Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. The Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.

  • Page 31: Connecting To Weld Output Terminals

    5-9. Connecting To Weld Output Terminals Stop engine. Positive (+) Weld Output Terminal Negative (−) Weld Output Terminal Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar Remove supplied nut from weld output termi-...

  • Page 32: Selecting Weld Cable Sizes

    5-10. Selecting Weld Cable Sizes* Weld Output Terminals Stop engine before Welding connecting to weld Amperes output terminals. Do not use worn, dam- aged, undersized, or poorly spliced cables. Chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable. **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.

  • Page 33: Connecting To Remote 14 Receptacle Rc14 On Cc/Cv Models

    5-12. Connecting To Remote 14 Receptacle RC14 On CC/CV Models New! LDR-14 long distance remote distance remote (includes 120 V receptacle) *The remaining sockets are not used. Notes Start Your Professional Welding Career Now! 24 VOLTS AC 24 VOLTS AC REMOTE OUTPUT OUTPUT...

  • Page 34: Section 6 − Operating Welding Generator − Cc Models

    SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 215 663 / 803 602 OM-4428 Page 30...

  • Page 35: Description Of Front Panel Controls For Cc Models (See Section 6-1)

    6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) Engine Starting Controls Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). Engine Control Switch Use switch to start and stop engine. To Start: NOTICE −...

  • Page 36: Remote Amperage Control On Cc Models (Optional)

    6-3. Remote Amperage Control On CC Models (Optional) Example: Combination Remote Amperage Control (Stick) Set Switches Set Range 6-4. Weld Control/Arc Condition Information Label OM-4428 Page 32 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-11). In Example: Range = 115 to 330 A DC Percentage Of Range = 50%...
  • Page 37 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-4428 Page 33...

  • Page 38: Section 7 − Operating Welding Generator − Cc/Cv Models

    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 OM-4428 Page 34...

  • Page 39: Description Of Front Panel Controls For Cc/Cv Models (See Section 7-1)

    7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) Engine Starting Controls Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). Engine Control Switch Use switch to start engine, select engine speed ( if unit has auto idle option), and stop engine.

  • Page 40: Process/Contactor Switch On Cc/Cv Models

    7-3. Process/Contactor Switch On CC/CV Models Switch Setting Switch Setting Remote On/Off Switch Re- GTAW With HF Unit, Pulsing quired − TIG, HF Required Device, Or Remote Control Or Scratch Start TIG Remote On/Off Switch Stick (SMAW) With Remote On/Off Required −...

  • Page 41: Remote Voltage/Amperage Control On Cc/Cv Models (Optional)

    7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) Example: Combination Remote Amperage Control (Stick) Set Remote Set V/A Adjust Switch Process Example: Combination Remote Amperage Control (TIG) Set V/A Set Remote Process Adjust Switch Process = Stick (Using Remote On/Off) Set Range Control Not Used In Remote...

  • Page 42: Section 8 − Operating Auxiliary Equipment

    SECTION 8 − OPERATING AUXILIARY EQUIPMENT 8-1. 120 Volt And 240 Volt Receptacles OM-4428 Page 38 120 V 20 A AC GFCI Receptacle GFCI1 240 V 30 A AC Twistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, GFCI Reset button...

  • Page 43: Connecting To Optional Three-Phase Generator (Cc/Cv Models Only)

    8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) Single-Phase Power Connection Three-Phase Power Connection Close panel opening if no connections are made to generator. Remove plug before inserting leads. Reinstall bushing. Rear Of Panel 120V 120V Single Phase Output Volts 120/240 Amps...

  • Page 44: Optional Generator Power Receptacles (Standard Models)

    8-3. Optional Generator Power Receptacles (Standard Models) European Receptacle Australian Receptacle South African Receptacle OM-4428 Page 40 120 V 20 A AC GFCI Receptacle GFCI1 240 V 16 A AC European Receptacle RC1 240 V 15 A AC Australian Receptacle RC1 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single-...

  • Page 45: Generator Power Receptacles (Export Models)

    8-4. Generator Power Receptacles (Export Models) Generator power is not affected by weld output. 130 V 32 A AC Receptacle RC1 220 Volt 16 A AC Receptacle RC2 130 Volt 16 A AC Receptacle RC3 Receptacles supply 60 Hz single-phase power at weld/power speed.

  • Page 46: Section 9 − Maintenance (Deutz F4L2011−Powered Units)

    SECTION 9 − MAINTENANCE (DEUTZ F4L2011−POWERED UNITS) 9-1. Maintenance Label (Deutz F4L2011-Powered Units) OM-4428 Page 42...

  • Page 47: Routine Maintenance (Deutz F4L2011-Powered Units)

    9-2. Routine Maintenance (Deutz F4L2011-Powered Units) n = Check Z = Change * To be done by Factory Authorized Service Agent Every FUEL WATER Hours n Fuel/Water Separator n Fuel Level Every Hours ~ Weld Terminals Every Hours ~ Battery Terminals n Air Cleaner Hoses Every Hours...

  • Page 48: Checking Generator Brushes

    9-3. Checking Generator Brushes Notes OM-4428 Page 44 Minimum Length: 5/8 in (16 mm) New Length: 1-1/4 in (32 mm) Replace Damaged Brushes Stop engine and let cool. 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.

  • Page 49: Servicing Air Cleaner (Deutz F4L2011-Powered Units)

    9-4. Servicing Air Cleaner (Deutz F4L2011-Powered Units) Keep nozzle 2 in (51 mm) from element. Blow Optional Inspect 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.

  • Page 50: Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units)

    9-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units) Tools Needed: 3/8 in OM-4428 Page 46 Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run at idle speed to blow out cleanout hole.

  • Page 51: Adjusting Engine Speed (Deutz F4L2011-Powered Units)

    9-6. Adjusting Engine Speed (Deutz F4L2011-Powered Units) Models With Automatic Idle (Optional) Tools Needed: 3/8, 7/16 in 1850 rpm Max. (61.6 Hz) 1250 rpm (41.5 Hz) Standard Models Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine no load speed with a tachometer or fre- quency meter (see table for no load...

  • Page 52: Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units)

    9-7. Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units) Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary Fuel Filter (Fuel/Water Sepa- rator)

  • Page 53: Overload Protection (Deutz F4L2011-Powered Units)

    9-8. Overload Protection (Deutz F4L2011-Powered Units) Ref. 803 657 Stop engine. When a supplementary protector, circuit breaker or fuse opens, it usu- ally indicates a more serious prob- lem exists. Contact Factory Autho- rized Service Agent. Fuse F1 Fuse F2 F1 and F2 protect the stator exciter winding from overload.

  • Page 54: Section 10 − Maintenance (Deutz F3L912−Powered Units)

    SECTION 10 − MAINTENANCE (DEUTZ F3L912−POWERED UNITS) 10-1. Maintenance Label (Deutz F3L912-Powered Units) OM-4428 Page 50...

  • Page 55: Routine Maintenance (Deutz F3L912-Powered Units)

    10-2. Routine Maintenance (Deutz F3L912-Powered Units) n = Check Z = Change * To be done by Factory Authorized Service Agent Every FUEL WATER Hours n Fuel/Water Separator n Fuel Level Every Hours ~ Weld Terminals Every Hours ~ Battery Terminals n Air Cleaner Hoses Every Hours...

  • Page 56: Checking Generator Brushes

    10-3. Checking Generator Brushes Notes OM-4428 Page 52 Minimum Length: 5/8 in (16 mm) New Length: 1-1/4 in (32 mm) Replace Damaged Brushes Stop engine and let cool. 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.

  • Page 57: Servicing Air Cleaner (Deutz F3L912-Powered Units)

    10-4. Servicing Air Cleaner (Deutz F3L912-Powered Units) Keep nozzle 2 in (51 mm) from element. Blow Optional Inspect 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.

  • Page 58: Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units)

    10-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units) Tools Needed: 3/8 in OM-4428 Page 54 Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run at idle speed to blow out cleanout hole.

  • Page 59: Adjusting Engine Speed (Deutz F3L912-Powered Units)

    10-6. Adjusting Engine Speed (Deutz F3L912-Powered Units) 10-7. Servicing Optional Ether Starting Aid (Deutz F3L912-Powered Units) 33 oz (935 g) Full Empty Engine Speed RPM (Hz) (No Load) 1850 Weld/Power (61.6 Hz) 15 oz (425 g) Stop engine. Engine speeds have been factory set and should not require adjust- ment.

  • Page 60: Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units)

    10-8. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary Fuel Filter (Fuel/Water Sepa- rator)

  • Page 61: Overload Protection (Deutz F3L912-Powered Units)

    10-9. Overload Protection (Deutz F3L912-Powered Units) Stop engine. When a supplementary protector, cir- cuit breaker or fuse opens, it usually in- dicates a more serious problem exists. Contact Factory Authorized Service Agent. Fuse F1 Fuse F2 F1 and F2 protect the stator exciter winding from overload.

  • Page 62: Section 11 − Troubleshooting

    SECTION 11 − TROUBLESHOOTING 11-1. Troubleshooting A. Welding − CC Models Trouble 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 5-11 and 6-1).
  • Page 63 B. Welding − CC/CV Models Trouble No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote okay at ac receptacles. On/Off Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-12 and 7-1).
  • Page 64 Trouble Low CV weld output. Set Ampere Range switch to highest range. Increase Voltage/Amperage Adjust Control setting. Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch. Repair or replace remote control device. Have Factory Authorized Service Agent check Amperage/Voltage Adjust Control R1, and field current regulator board PC1.
  • Page 65 E. Engine Trouble Engine will not crank. Check battery, and 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 9-8 or 10-9). Have Factory Authorized Service Agent check engine wiring harness and components. Check engine wiring harness plug connections.

  • Page 66: Section 12 − Electrical Diagrams

    SECTION 12 − ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For CC Welding Generator (Deutz F4L2011-Powered Units) OM-4428 Page 62...
  • Page 67 215 221-E OM-4428 Page 63...
  • Page 68 Figure 12-2. Circuit Diagram For CC Welding Generator (Deutz F4L2011-Powered Units) (Export Models) OM-4428 Page 64...
  • Page 69 235 275-A OM-4428 Page 65...
  • Page 70 Figure 12-3. Circuit Diagram For CC/CV Welding Generator (Deutz F4L2011-Powered Units) OM-4428 Page 66...
  • Page 71 215 806-E OM-4428 Page 67...
  • Page 72 Figure 12-4. Circuit Diagram For CC/CV Welding Generator (Deutz F4L2011-Powered Units) (Export Models) OM-4428 Page 68...
  • Page 73 235 276-A OM-4428 Page 69...
  • Page 74 Figure 12-5. Circuit Diagram For CC Welding Generator (Deutz F3L912-Powered Units) OM-4428 Page 70...
  • Page 75 215 807-D OM-4428 Page 71...
  • Page 76 Figure 12-6. Circuit Diagram For CC/CV Welding Generator (Deutz F3L912-Powered Units) OM-4428 Page 72...
  • Page 77 215 808-D OM-4428 Page 73...

  • Page 78: Section 13 − Run-In Procedure

    SECTION 13 − RUN-IN PROCEDURE 13-1. Wetstacking OM-4428 Page 74 run_in1 2007−04 NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.

  • Page 79: Run-In Procedure Using Load Bank

    13-2. Run-In Procedure Using Load Bank Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. NOTICE − Do not perform run- in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 80: Run-In Procedure Using Resistance Grid

    13-3. Run-In Procedure Using Resistance Grid OM-4428 Page 76 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. NOTICE − Do not perform run- in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 81: Section 14 − Generator Power Guidelines

    SECTION 14 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 14-1. Selecting Equipment 14-2. Grounding Generator To Truck Or Trailer Frame GND/PE Generator Power Receptacles −...

  • Page 82: Grounding When Supplying Building Systems

    14-3. Grounding When Supplying Building Systems 14-4. How Much Power Does Equipment Require? OM-4428 Page 78 GND/PE VOLTS 115 AMPS Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. Ground Device Use ground device as stated in electrical codes.
  • Page 83 14-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 14-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 84 14-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
  • Page 85 14-8. Power Required To Start Motor Motor Start Code KVA/HP 14-9. How Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements 10.0 AC MOTOR VOLTS AMPS CODE PHASE 11.2 12.5 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 86 14-10. Typical Connections To Supply Standby Power Utility Electrical Transfer Switch Service Essential Loads OM-4428 Page 82 Fused Welding Disconnect Generator Switch Output (If Required) Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install and ground this equipment according to its Owner’s Manual and na-...
  • Page 87 14-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 88: Section 15 − Parts List

    SECTION 15 − PARTS LIST Hardware is common and not available unless listed. A Deutz F4L2011 engine-pow- ered unit is shown below. See insert for parts specific to a Deutz F3L912-powered unit. Parts not related to the engines are the same in both units. 104 (FIG.
  • Page 89 A Deutz F4L2011 en- gine-powered unit is shown below. See in- sert for parts specific to a Deutz F3L912-pow- ered unit. Parts not re- lated to the engines are the same in both units. 35 (Fig. 15-6) Deutz F3L912 Engine 35 (Fig.
  • Page 90 Item Dia. Part Mkgs....189 824 ....♦199 294 ..
  • Page 91 Item Dia. Part Mkgs....♦174 064 ....♦175 937 .
  • Page 92 Item Dia. Part Mkgs....189 908 ....181 572 .
  • Page 93 Figure 15-2. Control Box Assembly − CC Models Item Dia. Part Mkgs. Figure 15-2. Control Box Assembly − CC Models (Figure 15-1 Item 98) ..F1, F2 *085 874 ....046 432 .
  • Page 94 Item Dia. Part Mkgs. Figure 15-2. Control Box Assembly − CC Models (Continued) ....215 013 ..PLG3 .
  • Page 95 Figure 15-3. Control Box Assembly − CC/CV Models Item Dia. Part Mkgs. Figure 15-3. Control Box Assembly − CC/CV Models (Figure 15-1 Item 98) ..F1, F2 *085 874 ....046 432 .
  • Page 96 Item Dia. Part Mkgs. Figure 15-3. Control Box Assembly − CC/CV Models (Continued) . . . 23 CB11, 12, 13 139 266 ..090 104 ....215 377 .
  • Page 97 Hardware is common and not available unless listed. Figure 15-4. Panel, Front w/Components − CC Models Item Dia. Part Mkgs. Figure 15-4. Panel, Front w/Components − CC Models (Figure 15-1 Item 104) ....215 663 .
  • Page 98 Item Dia. Part Mkgs. Figure 15-4. Panel, Front w/Components − CC Models (Continued) ....192 558 ...
  • Page 99 Item Dia. Part Mkgs. Figure 15-4. Panel, Front w/Components − CC Models (Continued) ... . 210 424 ..TEMP 217 084 ....197 798 .
  • Page 100 Hardware is common and not available unless listed. Figure 15-5. Panel, Front w/Components − CC/CV Models Item Dia. Part Mkgs. Figure 15-5. Panel, Front w/Components − CC/CV Models (Figure 15-1 Item 104) ....215 664 .
  • Page 101 Item Dia. Part Mkgs. Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued) ... . 193 234 .......
  • Page 102 Item Dia. Part Mkgs. Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued) . . . PC4, PC5 189 744 ....039 046 ....180 735 .
  • Page 103 Hardware is common and not available unless listed. Item Dia. Part Mkgs....132 053 ....183 387 .
  • Page 104 Item Dia. Part Mkgs....049 026 ....191 579 .
  • Page 105 Hardware is common and not available unless listed. Item Dia. Part Mkgs....215 910 ....188 137 .
  • Page 107 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.
  • Page 108 For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © 2007 Miller Electric Mfg. Co. 2007−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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