Miller Electric 500DX R Owner's Manual
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Miller Electric 500DX R Owner's Manual

Miller Electric 500DX R Owner's Manual

Engine driven welding generator
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www.MillerWelds.com
Big Blue 500DX
OM-129 647W
July 1999
Processes
Stick (SMAW) Welding
Air Carbon Arc (CAC-A) Cutting
and Gouging
With Optional Equipment:
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Engine Driven Welding Generator
R

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  • Page 1 Big Blue 500DX Visit our website at www.MillerWelds.com OM-129 647W July 1999 Processes Stick (SMAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging With Optional Equipment: MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Engine Driven Welding Generator...
  • Page 2 Warranty and Quality System Standard. service information for your 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 catalog sheets.

  • Page 3: Table Of Contents

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING WARNING This product, when used SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer.

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Marks a special safety message. Means “Note”; not safety related. 1-2.

  • Page 6: Noise Can Damage Hearing

    WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    MOVING PARTS can cause injury. D Keep away from fans, belts, and rotors. D Keep all doors, panels, covers, and guards closed and securely in place. D Stop engine before installing or connecting unit. D Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary.

  • Page 8: Principal Safety Standards

    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 9: Section 1 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANT 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Identifie un message de sécurité particulier. Signifie NOTA ;...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- cendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection. D Arrêter le moteur avant d’installer ou brancher l’appareil. D Demander seulement à...

  • Page 12: Principales Normes De Sécurité

    LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences. D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs. D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.

  • Page 13: Section 3 − Specifications

    SECTION 2 − DEFINITIONS 2-1. Symbols And Definitions Stop Engine Do Not Switch While Welding Check Injectors/ Pump Positive Amperes Stick (SMAW) Welding Time Three Phase SECTION 3 − SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Weld Welding Rated Welding Output Mode Output...

  • Page 14: Dimensions, Weights, And Operating Angles

    3-2. Dimensions, Weights, And Operating Angles Dimensions Height 47-5/8 in (1210 mm) Width 31-1/4 in (794 mm) Depth 60-1/2 in (1537 mm) 59-1/8 in (1502 mm) 47-1/4 in (1200 mm) 43-1/4 in (1099 mm) 32-3/4 in (832 mm) 24-15/16 in (633 mm) 10-1/2 in (267 mm) 6-1/2 in (165 mm) 2-7/8 in (73 mm)

  • Page 15: Duty Cycle And Overheating

    3-4. Duty Cycle And Overheating 6 Minutes Welding 3-5. AC Auxiliary Power 60% Duty Cycle At 500 Amperes 4 Minutes Resting Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit void...

  • Page 16: Volt-Ampere Curves

    3-6. Volt-Ampere Curves A. CC/DC (Standard) B. CV/DC (Models With CV Option) OM-129 647 Page 12 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 17: Optional Ac Power Plant Curves

    3-7. Optional AC Power Plant Curves The ac power curves show the auxiliary power in amperes avail- able at the single-phase 120/240 A. 7.5 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load) volt or three-phase 240 volt terminals. B. 10 KVA/KW Three-Phase Auxiliary Power Plant (No Weld Load) rsb13.1 12/94 - SB-005 185-B / SB-159 101-A OM-129 647 Page 13...

  • Page 18: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Installing Welding Generator Movement Do Not Lift Unit From End Grounding Electrically bond generator frame to vehicle frame by metal-to-metal contact. 4-2. Installing Exhaust Pipe Tools Needed: 1/2 in OM-129 647 Page 14 Airflow Clearance 18 in (460 mm) 18 in...

  • Page 19: Activating The Dry Charge Battery

    4-3. Activating The Dry Charge Battery 5 A For 30 Minutes 30 A For 12 Minutes − Remove battery from unit. Eye Protection − Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum).

  • Page 20: Connecting The Battery

    4-4. Connecting The Battery Tools Needed: 1/2 in 4-5. Engine Prestart Checks 1/2 in (13 mm) Full Diesel OM-129 647 Page 16 Connect Negative (−) Cable Last. − Full Valve Open ST-153 654-B / ST-180 933-B / S-0756-C Check all fluids daily. Engine must be cold and on a level surface.

  • Page 21: Connecting To Weld Output Terminals

    4-6. Connecting To Weld Output Terminals Left Side Tools Needed: 3/4 in 4-7. Selecting Weld Cable Sizes 100 ft (30 m) Or Less Welding Amperes Amperes 10 − 60% 60 − 100% Duty Cycle Duty Cycle *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. Contact your distributor for the mm equivalent weld cable sizes.

  • Page 22: Installing Ether Cylinder (Optional Ether Starting Aid)

    4-8. Installing Ether Cylinder (Optional Ether Starting Aid) 4-9. Remote A/V Control Receptacle RC3 OM-129 647 Page 18 Stop engine. Improper handling or expo- sure to ether can harm your health. Follow manufactur- er’s safety instructions on cylinder. Do not use Ether Starting Aid while engine is running.

  • Page 23: Remote 14 Receptacle Rc3 Information (Optional)

    4-10. Remote 14 Receptacle RC3 Information (Optional) C L N *The remaining sockets are not used. 4-11. Terminal Strip 2T Connections (Optional) Socket* Ref. ST-800 862-B Ref. ST 800 862 B Socket Information 24 volts ac. Protected by circuit breaker CB4. Contact closure to A completes 24 volts ac contactor control circuit.

  • Page 24: Section 5 − Operating The Welding Generator

    SECTION 5 − OPERATING THE WELDING GENERATOR 5-1. Standard Controls (See Section 5-2) ST-158 630-B / Ref. ST-158 631 / ST-180 933-B OM-129 647 Page 20...

  • Page 25: Description Of Standard Controls (See Section 5-1)

    5-2. Description Of Standard Controls (See Section 5-1) This unit has a max OCV control circuit that resets the Amperage/Voltage Con- trol to maximum when the arc breaks. When an arc is struck, weld output con- trol returns to the front panel or remote control setting.

  • Page 26: Controls For Models With Cv Option (See Section 5-4)

    5-3. Controls For Models With CV Option (See Section 5-4) ST-158 630-B / Ref. ST-158 631 / Ref. ST-185 762-B / S-185 440 OM-129 647 Page 22...

  • Page 27: Description Of Controls For Models With Cv Option (See Section 5-3)

    5-4. Description Of Controls For Models With CV Option (See Section 5-3) This unit has a max OCV control circuit that resets Amperage/Voltage Control R1 to maximum when the arc breaks. When an arc is struck, weld output con- trol returns to the R1 front panel or com- bination front panel/remote control setting.

  • Page 28: Volt And 240 Volt Duplex Receptacles

    SECTION 6 − OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt And 240 Volt Duplex Receptacles OM-129 647 Page 24 If unit does not have GFCI receptacles, use GFCI-pro- tected extension cord. 120 V 15 A AC Receptacle 240 V 15 A AC Receptacle Receptacles supply 60 Hz single- phase power at weld/power speed.

  • Page 29: Optional Auxiliary Power Receptacles

    6-2. Optional Auxiliary Power Receptacles Auxiliary power is not affected by weld output. If a circuit breaker continues to open, contact Factory Autho- rized Service Agent. GFCI Receptacle Option 120 V 15 A AC GFCI Receptacle GFCI1 Auxiliary power output and circuit breaker protection is the same as standard receptacles (see Section 6-1).

  • Page 30: Connecting Optional Auxiliary Power Plant

    6-3. Connecting Optional Auxiliary Power Plant 240V 240V 240V 240V 120V 120V Single Three Phase Phase Output Volts 120/240 Amps KVA/KW Frequency 60 Hz Engine Speed 1850 RPM Max. Fuse Size 35 Amperes Lead 42 connects to GROUND stud on front of unit.

  • Page 31: Section 7 − Maintenance & Troubleshooting

    SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance NOTE Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. Wipe Spills. Clean Air Filter. See Section 7-3. Clean And Tighten Battery Connections.

  • Page 32: Maintenance Label

    7-2. Maintenance Label See Engine Manual for complete engine care. Give Engine Specification and Serial Number when ordering parts. Check daily. Recommended Oil Oil Change & Filter Oil Filter Oil Capacity Fuel Capacity Fuel Grade Secondary Fuel Filter Primary Fuel Filter/ Diesel Water Separator Fill filter with clean fuel before installing −...

  • Page 33: Servicing Air Cleaner

    7-3. Servicing Air Cleaner Blow Inspect aircleaner1 4/96 − ST-153 929-B / ST-153 585 / Ref. ST-180 933-B / Ref. S-0698-B Stop engine. Do not run engine without air cleaner or with dirty element. Clean or replace element if dirty or damaged.

  • Page 34: Servicing Fuel And Lubrication Systems

    7-4. Servicing Fuel And Lubrication Systems Under Left Side Of Fuel Tank Valve Open Tools Needed: 3/8, 7/16, 3/4 in OM-129 647 Page 30 Stop engine and let cool. Oil Filter Oil Drain Plug Oil Drain Hose (Optional) Oil Fill Cap Primary Fuel Filter (Fuel/ Water Separator) Petcock...

  • Page 35: Adjusting Engine Speed

    7-5. Adjusting Engine Speed Right Side Tools Needed: 7-6. Servicing Optional Ether Starting Aid 33 oz (935 g) Full Empty Engine Speed (No Load) Weld/Power 3/8 in 15 oz (425 g) Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer.

  • Page 36: Checking And Replacing Alternator Belt

    7-7. Checking And Replacing Alternator Belt Tools Needed: 1/2, 11/16 in OM-129 647 Page 32 1/2 in (13 mm) Stop engine. To check belt tension: Remove rear panel. Alternator V-Belt Crank Pulley Alternator Pulley Place straight edge along top of pulleys.

  • Page 37: Resetting Fan Belt Safety Shutdown

    7-8. Resetting Fan Belt Safety Shutdown Right Side Tools Needed: 3/8 in Stop engine. Cooling Fan V-Belt See engine manual to replace or tighten belt. If belt breaks or becomes loose, safety shutdown stops engine. Correct problem, then reset safety shutdown as follows: Stop Bracket...

  • Page 38: Inspecting And Cleaning Optional Spark Arrestor Muffler

    7-9. Inspecting And Cleaning Optional Spark Arrestor Muffler Tools Needed: 3/8 in 7-10. Overload Protection For Models With CV Option OM-129 647 Page 34 Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole.

  • Page 39: Troubleshooting

    7-11. Troubleshooting A. Welding Trouble No weld output. Check position of Ampere Range switch. Check position of optional polarity switch. Disconnect equipment from auxiliary power receptacles during start-up. Place A/V Control switch in Panel position, or place switch in Remote position and connect remote con- trol to Remote A/V Control receptacle RC3 (see Sections 4-9 and 5-1).

  • Page 40: Auxiliary Power

    Trouble Repair or replace remote control device. Have Factory Authorized Service Agent check optional CV regulator board PC2. B. Auxiliary Power Trouble output auxiliary power Reset receptacle circuit breakers. receptacles. Have Factory Authorized Service Agent check brushes and slip rings, and optional field current regula- tor board PC1.
  • Page 41 Trouble Periodically recharge battery (approximately every 3 months). Engine uses oil during run-in period; Dry engine (see Section 9). wetstacking occurs. Remedy OM-129 647 Page 37...
  • Page 42 Notes OM-129 647 Page 38...

  • Page 43: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS 180 941-A Figure 8-1. Circuit Diagram For Welding Generator (Standard Models) OM-129 647 Page 39...
  • Page 44 Figure 8-2. Circuit Diagram For Welding Generator (Models With CV Option) OM-129 647 Page 40...
  • Page 45 184 954-C OM-129 647 Page 41...

  • Page 46: Section 9 − Run-In Procedure

    SECTION 9 − RUN-IN PROCEDURE 9-1. Wetstacking OM-129 647 Page 42 Welding Generator Run diesel engines near rated output during run-in period to prop- erly seat piston rings and prevent wetstacking. See nameplate or rating label to find rated output. Do not idle engine longer than necessary.

  • Page 47: Run-In Procedure Using Load Bank

    9-2. 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. Load Bank Turn all load bank switches Off. If needed, connect load bank to 115 volts ac wall receptacle or genera- tor auxiliary power receptacle.

  • Page 48: Run-In Procedure Using Resistance Grid

    9-3. Run-In Procedure Using Resistance Grid OM-129 647 Page 44 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. Resistance Grid Use grid sized for generator rated output. Turn Off grid. Welding Generator Place A/V range switch in maxi- mum position, A/V control in mini-...

  • Page 49: Section 10 − Auxiliary Power Guidelines

    SECTION 10 − AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment 10-2. Grounding Generator To Truck Or Trailer Frame Be sure equipment has this symbol and/or wording. GND/PE Electrically bond generator frame to vehicle frame by metal-to-metal contact. Auxiliary Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double...

  • Page 50: Grounding When Supplying Building Systems

    10-3. Grounding When Supplying Building Systems 10-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
  • Page 51 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 10-6. 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 52 10-7. 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 53: Power Required To Start Motor

    10-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
  • Page 54 10-10. Typical Connections To Supply Standby Power Customer-supplied equipment is required if generator is to supply standby power during emergencies or power outages. 120/240 Volt 60 Hz Three-Wire Service Load 120/240 Volt Single-Phase Three-Wire Generator Output Connection OM-129 647 Page 50 240 V 120 V 120 V...

  • Page 55: Selecting Extension Cord (Use Shortest Cord Possible)

    10-11. 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 56: Section 10 − Parts List

    SECTION 11 − PARTS LIST Hardware is common and not available unless listed. Fig 11-2 Fig 11−6 & Fig 11-7 OM-129 647 Page 52 Fig 11-5 Figure 11-1. Main Assembly...
  • Page 57 Fig 11-3 ST-048 455-AA OM-129 647 Page 53...
  • Page 58 Item Dia. Part Mkgs....134 771 ....184 675 TANK, fuel 23gal (consisting of) .
  • Page 59 Item Dia. Part Mkgs......SPRING, (included w/engine − see engine parts list) ... . 181 634 ENGINE, diesel electric (consisting of) .
  • Page 60 Hardware is common and not available unless listed. Figure 11-2. Panel, Front w/Components (CC Model Illustrated) OM-129 647 Page 56 Fig 11-4 ST-048 457-N...
  • Page 61 Item Dia. Part Mkgs....154 292 ... 171 878 SWITCH, range (Fig 11-4) ..
  • Page 62 Hardware is common and not available unless listed. SD-048 456-E Figure 11-3. Generator OM-129 647 Page 58...
  • Page 63 Item Dia. Part Mkgs....106 426 ....106 440 BUS BAR, rectifier .
  • Page 64 Item Dia. Part Mkgs. 171 878 Figure 11-4. Switch, Range (Fig 11-2 Item 2) ..114 235 BRACKET, mtg switch range (consisting of) ..010 671 .
  • Page 65 Item Dia. Part Mkgs. Figure 11-5. Control Box CC/CV (Figure 11-1 Item 86) (Optional) ..605 321 NUT, .468-32 brs blk ..011 611 SWITCH, tgl DPDT 15A 125V S8,9 011 609 SWITCH, tgl SPDT 15A 125V...
  • Page 66 Item Dia. Part Mkgs. Figure 11-6. Panel, Mtg Components (CC/CV Model) (Figure 11-1 Item 87) ..185 748 RESISTOR BOARD SR1,4 035 704 RECTIFIER, integ 40A 800V ..192 307 KIT, diode w/washers .
  • Page 67 Item Dia. Part Mkgs. Figure 11-7. Panel, Mtg Components (CC Model) (Figure 11-1 Item 87) ..170 672 PANEL, mtg components ..030 844 RESISTOR, WW fxd 25W 250 ohm .
  • Page 69 Call LIMITED WARRANTY − Subject to the terms and conditions 1-800-4-A-MILLER below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
  • Page 70 Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 1999 Miller Electric Mfg. Co. 7/99 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA &...

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