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OM-285665E 2022-05 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Stick (SMAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Big Blue 500X Pro ® Deutz OWNER’S MANUAL For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
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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.
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING 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 not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
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Accidental contact of electrode to metal objects can cause sparks, ex- FLYING METAL OR DIRT can injure plosion, overheating, or fire. Check and be sure the area is safe be- eyes. fore doing any welding. � Welding, chipping, wire brushing, and grinding �...
� Install cylinders in an upright position by securing to a stationary � Turn face away from valve outlet when opening cylinder valve. Do support or cylinder rack to prevent falling or tipping. not stand in front of or behind the regulator when opening the valve.
1-4. Compressed Air Hazards � Reinstall doors, panels, covers, or guards when servicing is fin- COMPRESSED AIR EQUIPMENT can ished and before starting unit. injure or kill. � If ANY air is injected into the skin or body seek medical help immediately.
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� Follow the guidelines in the Applications Manual for the Revised HIGH PRESSURE FLUIDS can injure NIOSH Lifting Equation (Publication No. 94-110) when manually or kill. lifting heavy parts or equipment. � Engine fuel system components can be under high OVERHEATING can damage motors.
� If notified by the FCC about interference, stop using the equipment � Be sure all equipment in the welding area is electromagnetically at once. compatible. � Have the installation regularly checked and maintained. � To reduce possible interference, keep weld cables as short as �...
SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION 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.
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� Ne pas toucher aux portes-électrodes qui sont raccordés à deux bien ventilé, et en portant un respirateur à alimentation d’air. Les machines à souder en même temps, car cela entraîne la présence revêtements et tous les métaux renfermant ces éléments peuvent d’une tension de circuit-ouvert double.
� Ne pas souder là où l’air ambiant pourrait contenir des poussières, � Les porteurs d’implants médicaux doivent consulter leur médecin gaz ou émanations inflammables (vapeur d’essence, par et le fabricant du dispositif avant de s’approcher de la zone où se exemple).
� Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces � Ne pas toucher aux pièces chaudes, utiliser les outils recomman- inflammables. dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. � Tenir à distance les produits inflammables de l’échappement. LA VAPEUR ET LE LIQUIDE DE Les PIÈCES MOBILES peuvent REFROIDISSEMENT CHAUD peuvent...
L’AIR COMPRIMÉ risque de Les PIÈCES MOBILES peuvent provoquer des blessures ou même la causer des blessures. mort. � S’abstenir de toucher des parties mobiles telles � Avant d’intervenir sur le circuit d’air comprimé, que des ventilateurs, courroies et rotors. couper l’alimentation électrique, verrouiller etéti- �...
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� Utiliser uniquement des équipements adéquats pour un fonction- � Régler les commandes de charge de batterie sur la position d’arrêt nement avec une alimentation de 50/60 ou de 60 Hz. avant de brancher la batterie. Veiller à ce que les pinces de charge ne se touchent pas.
� Effectuer l’installation, l’entretien et toute intervention selon les LE SOUDAGE À L’ARC risque de manuels d’utilisateurs, les normes nationales, provinciales et de provoquer des interférences. l’industrie, ainsi que les codes municipaux. � L’énergie électromagnétique risque de provoquer LE RAYONNEMENT HAUTE des interférences pour l’équipement électronique FRÉQUENCE (H.F.) risque de sensible tel que les ordinateurs et l’équipement...
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les porteurs d’implants médicaux doivent être prises: par exemple, 5. Connecter la pince sur la pièce aussi près que possible de la des restrictions d’accès pour les passants ou une évaluation indivi- soudure. duelle des risques pour les soudeurs. Tous les soudeurs doivent ap- 6.
Some symbols are found only on CE products. facility. Some symbols are found only on CE products. Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Contact your local recycling office or your local distributor for further information. Safe �...
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Turn off power before disassembling torch. � Complete Parts List is available at www.MillerWelds.com Safe19 201 Do not remove or paint over (cover) the label. Do not remove or paint over (cover) the label. Safe20 201 Writer: If necessary, replace the word “handle” with “lift eye’. Do not use one handle to lift or support unit.
Connect green or green/yellow grounding conductor to ground Connect green or green/yellow grounding conductor to groun Connect green or green/yellow grounding conductor to ground Connect green or green/yellow grounding conductor to groun terminal. terminal. terminal. terminal. Connect input conductors (L1, L2 And L3) to line terminals. Connect input conductors (L1, L2 And L3) to line terminals.
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Voltage (OCV) Air Carbon Arc ymbol Definitions Conventional Cutting (CAC-A) Idle (Slow) � Load Voltage Complete Parts List is available at www.MillerWelds.com Shielded Metal Arc Welding Battery (Engine) Rotating Knob 242a Rated Press Or Turn (SMAW) And Push Button Engine Oil Voltage Engine Choke Current...
Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...
� Complete Parts List is available at www.MillerWelds.com 4-6. Environmental Specifications A. IP Rating IP Rating IP23S This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless sheltered.
� Complete Parts List is available at www.MillerWelds.com Stick 4-8. Volt-Ampere Curves Stick Stick The volt-ampere curves show the minimum Stick and maximum voltage and amperage output capabilities of the welder/generator. Curves of other settings fall between the curves shown. DC AMPERES DC AMPERES DC AMPERES...
� Complete Parts List is available at www.MillerWelds.com 4-9. Export Generator Power Curves Single Phase 4 kW The AC power curves show the generator Single Phase 4 kW power output in amperes. AC AMPERES Three Phase 15 kW (400 V) AC AMPERES Three Phase 15 kW (400 V) Three Phase 15 kW (400 V)
� Complete Parts List is available at www.MillerWelds.com 4-10. Fuel Consumption The curve shows typical fuel use under weld or power loads. 2.50 2.25 2.00 1.75 1.50 1.25 1.00 0.75 0.50 IDLE 0.25 0.00 DC WELD AMPERES AT 100% DUTY CYCLE 269535 A OM-285665 Page 3 OM-285665 Page 23...
� Complete Parts List is available at www.MillerWelds.com SECTION 5 – INSTALLATION 5-1. Installing Welder/Generator Movement And Airflow Clearance 18 in. 18 in. (460 mm) (460 mm) 18 in. 18 in. (460 mm) 18 in. 18 in. (460 mm) (460 mm) (460 mm) 18 in.
� Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator to Truck or Trailer Frame 1-1. Grounding Generator To Truck Or Trailer Frame GND/PE Bed liners, shipping skids, and 1 Equipment Grounding Terminal Always ground generator frame to some running gear insulate the Front Panel) vehicle frame to prevent electric welding generator from the vehicle...
� Complete Parts List is available at www.MillerWelds.com 5-4. Connecting The Battery 907736 / Ref. 907561 01 2-1. Connecting The Battery 1/2 in. Battery is most easily accessed through the � Never start the engine when the cables NOTICE – Lead acid batteries discharge ps head wrench crescent wrench...
Avoid these issues by considering the following recommendations: � Weather Protection. Use a Miller Cold Weather Kit (Miller part no. 301482). Additional measures may be taken to shield the unit from the elements such as using wind barriers to reduce air flow.
� Complete Parts List is available at www.MillerWelds.com 5-6. Weld Output Terminals 285716 / 907603 TP3 285716 OM-285665 Page 6 3/4 in. For Stick and TIG Direct Current Electrode cable to Negative (-) terminal on right. Use Stop engine. ps head wrench crescent wrench Negative (DCEN), connect electrode holder...
� Complete Parts List is available at www.MillerWelds.com 5-8. Selecting Cable Sizes* NOTICE – The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.
SECTION 1 OPERATING WELDER / GENERATOR � Complete Parts List is available at www.MillerWelds.com SECTION 6 – OPERATION 1-1. Front Panel Controls (See Section NO TAG) 6-1. Front Panel Controls (See Section 6-2) 282033-A OM-285665 Page 7 OM-285665 Page 30...
See Section 6-3 for Process/Contactor output amperage when welding. applied. switch information. NOTICE – Diesel engines in Miller equip- To set amperage, turn Process/Contactor ment are meant to operate optimally at mod- 7 Adjust Control/Select Button switch to Stick or TIG position. Turn V/A erate to rated load.
� Complete Parts List is available at www.MillerWelds.com 6-3. Process/Contactor Switch 1 Process/Contactor Switch Weld output terminals are energized when Process/Contactor switch is in an Electrode Hot position and the en- gine is running. Use switch to select weld process and weld output on/off control (see table below).
� Complete Parts List is available at www.MillerWelds.com 6-4. Service Menu 1 Adjust Control/Select Button Press and hold control for 5 seconds, then re- lease to access the Service Menu. Rotate the knob to scroll through the menu items. Press and release the control to access the options and information within each menu item.
� Complete Parts List is available at www.MillerWelds.com Voltage sensing feeder � (0) GTAW (TIG Lift Arc ™ Starting point. STOP Auto-Stop sensitivity (from most sensitive [-5] to least sensi- (–5 to 5) tive [5]) Auto-Stop determines the arc length (voltage) threshold the operator must exceed to terminate the arc.
Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it. � Miller recommends Hobart filler metals. OM-285665 Page 35...
Remote control is not needed when us- ing Auto-Crater. 1. While welding. 2. Lift torch slightly to start Auto-Crater end (current is reduced). 3. Lower torch. Weld current ramps down. 4. Shielding gas continues until shut off. � Miller recommends Hobart filler metals. OM-285665 Page 36...
� Complete Parts List available at www.MillerWelds.com Complete Parts List is available at www.MillerWelds.com 6-9. Remote Voltage/Amperage Control 1-1. Voltage/Amperage Control With 14-Pin Remote Accessory Remote Receptacle Connect optional remote control to receptacle. Ref. 907761 When a remote control is con- Big Blue 800 Duo Air Pak shown.
� Complete Parts List is available at www.MillerWelds.com 6-10. Updating Software When the machine has powered up, if valid During the download, the left meter display Obtain the latest firmware to be loaded from files exist on the flash drive, the user is indicates the active download with ALLC, MillerWelds.com prompted to confirm the start of the down-...
� Complete Parts List is available at www.MillerWelds.com 6-11. Summary File 1 Summary File Each time a USB stick is inserted in the USB receptacle, a summary file is saved to the USB stick as SummaryFile.txt. "USB ACC" will display as the file is written. File is complete when display no longer shows "USB ACC."...
� Complete Parts List is available at www.MillerWelds.com 6-13. Associating ArcReach Devices (ArcReach Models Only) ® Stop engine. NOTICE – Do not exceed machine duty cycle. Associating ArcReach Device To Engine Driven Welder/Generator Make connections between welder/generator and ArcReach device. See Owner’s Manual for ArcReach device for typical connection diagrams.
� Complete Parts List is available at www.MillerWelds.com 6-14. Operating Oil Pan Heater 1 Oil Pan Heater Plug Use heater to maintain a constant engine oil temperature. To turn on heater, connect heater plug to 120 volts AC receptacle. Heater rated at 300 watts.
� Complete Parts List is available at www.MillerWelds.com SECTION 7 – OPERATING AUXILIARY EQUIPMENT 7-1. Export Auxiliary Power Receptacles SECTION 2 OPERATING AUXILIARY EQUIPMENT 282760-A 6 Supplementary Protector CB1 (Deluxe 10 Supplementary Protector CB8 1 110 V 16 A AC Receptacle RC1 Model) 2 220 V 16 A AC Receptacle RC3 CB8 protects GFCI2 and RC2 from over-...
� Complete Parts List is available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting, And Testing Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles auxiliary equipment. If unit does not button pops out, and the circuit opens to dis- If a GFCI fault occurs, stop engine and dis- have GFCI receptacles, use GFCI- connect power to the faulty equipment.
� Complete Parts List is available at www.MillerWelds.com SECTION 3 MAINTENANCE AND TROUBLESHOOTING SECTION 8 – MAINTENANCE AND TROUBLESHOOTING 8-1. Maintenance Label OM-285665 Page 12 OM-285665 Page 45...
The engine will begin to start and then stop. � Trouble: Oil level is too high. Symptom: The pressure line that When servicing a Miller gasoline-powered welder/generator, always perform the following basic Recycle engine fluids. operates the fuel pump can be plugged. Not enough fuel will be delivered, and the engine will not run or will run poorly.
� Complete Parts List is available at www.MillerWelds.com NOTE: This standard is now used for IED/PED models with plastic air cleaner housing. 8-3. Servicing Air Cleaner Stop engine. NOTICE – Do not run engine without air cleaner or with dirty element. Engine dam- age caused by using a damaged element is not covered by the warranty.
� Complete Parts List is available at www.MillerWelds.com 8-4. Adjusting Engine Speed Every 6000 Hours or 5 Years Stop engine and let cool. � For operation at high altitude, engine may require adjustment. If adjustment is necessary, contact engine manufac- turer’s Factory Authorized Service Agent.
� Complete Parts List is available at www.MillerWelds.com 8-5. Checking Generator Brushes Stop engine and let cool. 1 Generator Brush 2 Minimum Length: 5/8 in. (16 mm) 3 New Length: 1–1/4 in. (32 mm) 4 Damaged Brush Mark and disconnect leads at brushholder cap.
� Complete Parts List is available at www.MillerWelds.com 8-8. Servicing Fuel And Lubrication Systems 285716 / 907 603 TP3 tools/ maintenance label for oil/filter change Close doors. Stop engine and let cool. flathead philips head wrench crescent wrench information. To drain sludge from fuel tank: After servicing, start engine and To replace fuel filters: check for fuel leaks.
� Complete Parts List is available at www.MillerWelds.com 8-9. Overload Protection 285716 F1 and F2 protect the stator exciter winding up and weld and generator power output Stop engine. from overload. If F1 opens, weld and gener- may not be available. ator power is low or stops entirely.
� Complete Parts List is available at www.MillerWelds.com 8-10. Voltmeter/Ammeter Error Displays Display Example Use the Voltmeter/Ammeter error displays to diagnose and correct fault conditions. � When an error is displayed, normally weld output has stopped but generator power output may be okay. �...
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� Complete Parts List is available at www.MillerWelds.com Trouble Remedy High weld output. Check position of Voltage/Amperage Adjust control. Have Factory Authorized Service Agent check voltage feedback circuit. Low weld output. Check position of Voltage/Amperage Adjust control. Check fuses F1 and F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check integrated rectifier SR2, capacitor C6, and the rotor.
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� Complete Parts List is available at www.MillerWelds.com D. Engine Trouble Remedy Engine will not crank. Supplementary protector CB2 open. Reset CB2. Check battery connections and tighten if necessary. Check battery, and replace if necessary. Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8- 9).
� Complete Parts List is available at www.MillerWelds.com SECTION 9 – PARTS LIST 9-1. Recommended Spare Parts Item No. Dia. Mkgs. Part No. Description Quantity F1, F2 085874 Fuse, Mintr Cer Slo-blo 10. Amp 250 Volt 190823 Brush, Contact Elect .250 X.500 X 1.250 Grd Ay 192939 Filter, Air Element Safety 246988...
SECTION 11 – RUN-IN PROCEDURE NOTICE – Diesel engines in Miller equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended peri- ods of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.
11-2. Run-In Procedure Using Load Bank Or Resistance Grid Stop engine. 3 Weld Cables Set grid switches and then adjust gener- ator A/V control so load equals rated 4 Resistance Grid Do not touch hot exhaust pipe, en- voltage and current of the generator (see gine parts, or load bank/grid.
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 1 Generator Power Receptacles – Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated...
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12-3. Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable GND/PE Use #8 AWG or larger insulated copper wire. 3 Ground Device � Use ground device as stated in electri- cal codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wir- ing system.
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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...
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Farm/Home Equipment Rating Starting Watts Running Watts Refrigerator or Freezer 3100 Shallow Well Pump 1/3 HP 2150 1/2 HP 3100 1000 Sump Pump 1/3 HP 2100 1/2 HP 3200 1050 12-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment Rating Starting Watts Running Watts Hand Drill...
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12-8. Power Required To Start Motor 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage AC MOTOR VOLTS AMPS Step 1: Find code and use table to find kVA/ CODE HP. If code is not listed, multiply running am- PHASE perage by six to find starting amperage.
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12-10. Typical Connections To Standby Power 1. Utility Electrical 2. Transfer Switch 3. Fused Disconnect 4. Welder/Generator Service Switch (If Required) Output 5. Essential Loads Have only qualified persons perform 1 Utility Electrical Service 4 Welder/Generator Output these connections according to all 2 Transfer Switch (Double-Throw) Generator output voltage and wiring must applicable...
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12-11. Selecting Extension Cord (Use Shortest Cord Possible) A. Cord Lengths For 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm Current (Amperes)
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Effective January 1, 2022 (Equipment with a serial number preface of NC or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. � Field Options (NOTE: Field options are cov-...
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