Miller Big Blue 500X Eco Pro Owner's Manual
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Miller Big Blue 500X Eco Pro Owner's Manual

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Big Blue 500X Eco Pro
OM-242 702P
2012−04
Processes
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
File: Engine Drive

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Summary of Contents for Miller Big Blue 500X Eco Pro

  • Page 1 OM-242 702P 2012−04 Processes Processes TIG (GTAW) Welding Stick (SMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator Big Blue 500X Eco Pro 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.

  • 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.

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

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2011−10 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 6 D Do not weld on containers that have held combustibles, or on FUMES AND GASES can be hazardous. closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Welding produces fumes and gases. Breathing these Safety Standards).

  • Page 7: 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 protective clothing when working on a battery. D Use approved engine exhaust spark arrestor in required areas —...

  • Page 8: 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 9 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 protective store, move, or ship PC boards.

  • Page 10: 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 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2011−10 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 12 Il reste une TENSION DC NON NÉGLIGEABLE dans les LES RAYONS DE L’ARC peuvent sources de soudage onduleur UNE FOIS le moteur coupé. provoquer des brûlures dans les yeux et sur la peau. D Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué...

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, LE BRUIT peut affecter l’ouïe. des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. Le bruit des processus et des équipements peut D Placer les bouteilles debout en les fixant dans un support station- affecter l’ouïe.

  • Page 14: Dangers Liés À L'air Comprimé

    LA VAPEUR ET LE LIQUIDE DE L’ACIDE DE LA BATTERIE peut pro- REFROIDISSEMENT CHAUD peuvent voquer des brûlures dans les YEUX et provoquer des brûlures. sur la PEAU. D Il est préférable de vérifier le liquide de refroi- D Ne pas renverser la batterie. dissement une fois le moteur refroidi pour éviter D Remplacer une batterie endommagée.

  • Page 15: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    détendre la pression et s’assurer que le circuit d’air ne peut être L’INHALATION D’AIR COMPRIMÉ risque mis sous pression par inadvertance. de provoquer des blessures ou même D Demander seulement à un personnel qualifié d’enlever la mort. les dispositifs de sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.
  • Page 16 LA SORTIE DE RECHARGE et L’EXPLO- LES CHARGES ÉLECTROSTATI- SION BATTERIE peuvent QUES peuvent endommager les provoquer des blessures. circuits imprimés. D Établir la connexion avec la barrette de terre La recharge de batterie n’existe pas sur tous les avant de manipuler des cartes ou des pièces. modèles.

  • Page 17: 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 18: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Wordless Label Definitions Electric shock from welding Warning! Watch Out! There are possible hazards as electrode or wiring can kill. shown by the symbols. 1.1 Wear dry insulating gloves. Do Become trained and read the instructions before working on the not touch electrode with bare hand.

  • Page 19: Warning Label Definitions

    3-2. Warning Label Definitions Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. Read Owner’s Manual. Read labels on unit. Use Diesel Fuel only, and fill fuel tank. Leave room for expansion. Warning! Watch Out! There are possible hazards as shown by the symbols.

  • Page 20: Symbols And Definitions

    3-3. Symbols And Definitions Some symbols are found only on CE products. Fast (Run, Weld/ Stop Engine Slow (Idle) Start Engine Power) Starting Aid Engine Oil Battery (Engine) Engine Oil (Preheat) Pressure Check Injectors/ Check Valve Protective Earth Fuel Pump Clearance (Ground) Certified/Trained...

  • Page 21: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Maximum Weld Welding Rated Welding Open- Auxiliary Power Fuel Output Engine Mode Output Circuit Rating Capacity Rating Range Voltage 300 A, 32 Volts DC Auxiliary power 100% Duty Cycle CC/DC 40 −...

  • Page 22: Cc Volt-Ampere Curves

    4-3. CC Volt-Ampere Curves A. Stick Mode The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. 350A−ECONOMY MODE MAX−POWER MODE (GOUGE) (GOUGE) MAX−POWER MODE MIN−ECONOMY MODE DC AMPERES...

  • Page 23: Cv (Fcaw) Volt-Ampere Curves

    4-4. CV (FCAW) Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. MAX − ECONOMY MODE MAX − POW ER MODE MIN −...

  • Page 24: Duty Cycle And Overheating

    4-6. Duty Cycle And Overheating 100% Duty Cycle Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. This unit is rated for welding at 300 amperes continuously. NOTICE − Exceeding duty cycle can damage unit and void warranty.

  • Page 25: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Locations 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. For future reference, write serial number in space provided on back cover of this manual. 5-2.

  • Page 26: Mounting Welding Generator

    5-3. Mounting Welding Generator Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. Supporting The Unit NOTICE − Do not mount unit by supporting the base only at the four mounting brackets.

  • Page 27: Grounding Generator To Truck Or Trailer Frame

    5-4. Grounding Generator To Truck Or Trailer Frame GND/PE rot_grnd2 2012−03 − 800 652-D frame. Always connect a ground Equipment Grounding Terminal (On Always ground generator frame to wire from the generator equipment Front Panel) vehicle frame to prevent electric grounding terminal to bare metal on shock and static electricity hazards.

  • Page 28: Connecting The Battery

    5-6. Connecting The Battery Connect negative (−) battery cable last. Close door after connecting battery. − Shown with rocker panel removed. Tools Needed: 1/2 in. Conn_Batt2 2010−04 / S-0756-C / 161-002 Notes OM-242 702 Page 24...

  • Page 29: Engine Prestart Checks

    5-7. Engine Prestart Checks NOTICE − Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe, see Section 10. Check radiator coolant Full level when fluid is low in recovery tank. Diesel Full Engine stops if fuel level is low.

  • Page 30: Weld Output Terminals

    5-8. Weld Output Terminals 287 1255-A Work (−) Weld Output Terminal Electrode Positive (DCEP), connect elec- er cable to Positive (+) terminal and work trode holder cable to Positive (+) terminal cable to Negative (−) terminal on left. Stick / TIG / FCAW Positive (+) Weld and work cable to Negative (−) terminal on Output Terminal left.

  • Page 31: Selecting Weld 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-J 2011−07 Notes...

  • Page 32: Connecting To Remote 14 Receptacle Rc14

    5-11. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information Not all models have contactor control. See description of front panel controls and circuit diagram. 24 volts AC. Protected by supplementary protector. 24 VOLTS AC Contact closure to A completes 24 volt AC contactor control circuit.
  • Page 33 Notes OM-242 702 Page 29...

  • Page 34: Section 6 − Operating Welding Generator

    SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls (See Section 6-2) 287 125−A / 804 009−F OM-242 702 Page 30...

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

    6-2. Description Of Front Panel Controls (See Section 6-1) Engine Starting Controls Weld Controls CAC-A / Stick Position Preheat Switch Remote Control Receptacle For gouging (CAC-A), place Engine Control switch in 350−500 Amps position. The engine Use switch to energize starting aid for cold This unit is equipped with 24 volts AC runs at 3000 RPM and auxiliary power is not weather starting (see starting instructions fol-...

  • Page 36: Remote Voltage/Amperage Control

    6-3. Remote Voltage/Amperage Control Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-11). When a remote control is con- nected to the Remote receptacle, the Auto Sense Remote feature automatically switches voltage/ amperage control to the remote control.

  • Page 37: Operating Optional Engine Block Heater

    6-4. Operating Optional Engine Block Heater Engine Block Heater Plug Use heater to maintain a constant engine oil temperature. Block heater specifications: 400 Watts, 3 Amperes at 115/120 Volts AC. To turn on heater, connect heater plug to 120 volts AC receptacle. Do not run engine while oil pan heater is on.

  • Page 38: Fuel/Hour Gauge Descriptions

    6-5. Fuel/Hour Gauge Descriptions OM-242 702 Page 34...

  • Page 39: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Auxiliary Power Receptacles Ref. 239 397 have GFCI receptacles, use GFCI- LED blinks, stop using GFCI recept- When Engine Control switch is in protected extension cord. Do not acle and have it replaced by a Fact- 350−500 Amps position (engine locked use GFCI receptacle to power life ory Authorized Service Agent.

  • Page 40: Gfci Receptacle Information, Resetting And Testing

    7-2. GFCI Receptacle Information, Resetting And Testing RotGFCI1 2012−03 If a ground fault is detected, the GFCI Reset plugs, etc. connected to the receptacle. Use GFCI protection when operat- button pops out, the LED lights, and the cir- Start engine and connect equipment (light, ing auxiliary equipment.

  • Page 41: Section 8 − Maintenance & Troubleshooting

    SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Maintenance Label Mitsubishi Engine North America 1250 Greenbriar Dr., Suite E Addison, IL 60101 630−268−0750 Http://www.mitsubishi−engine.com Use web site to locate closest dealer. For in- ternational information, use: Http://www/mhi/co/jp/global/network OM-242 702 Page 37...

  • Page 42: Routine Maintenance

    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. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent...

  • Page 43: Servicing Air Cleaner

    8-3. Servicing Air Cleaner Blow Keep nozzle 2 in. (51 mm) from element. Inspect Optional aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 226 386-B ment, we strongly recommend instal- To clean air filter: Stop engine. ling an optional safety element to pro- Wipe off cap and housing.

  • Page 44: Inspecting And Cleaning Spark Arrestor Muffler

    8-5. Inspecting And Cleaning Spark Arrestor Muffler Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhaust pipe with fireproof material.

  • Page 45: Servicing Fuel And Lubrication Systems

    8-7. 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. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary (Canister) Fuel Filter Location Fuel Filter Retaining Ring...

  • Page 46: Overload Protection

    8-8. Overload Protection Stop engine. When a circuit breaker, supple- mentary protector, or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. Fuse F1 F1 protects the stator exciter wind- ing from overload. If F1 opens, weld and generator power is low or stops entirely.

  • Page 47: Adjusting Engine Speed

    8-9. Adjusting Engine Speed The engine is electronically governed. Engine speed adjustment must be done by an engine Factory Authorized Service Agent. Tampering with adjustments may affect engine warranty. 8-10. Voltmeter/Ammeter Help Displays (Models With Optional Meters) HL.P HL.P HL.P HL.P HL.P 217 357-A...

  • Page 48: Troubleshooting

    8-11. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10). A. Welding Trouble Remedy No weld output; generator power output Have Factory Authorized Service Agent check main rectifier and main control module PC1. okay at AC receptacles. Reset supplementary protector CB8 (see Section 8-8).
  • Page 49 B. Standard Generator Power Trouble Remedy No generator power output at AC recep- Reset receptacle supplementary protectors (see Section 7-1). tacles; weld output okay. Change engine control switch to 20−350 Amps position. No generator output and remote con- Have Factory Authorized Service Agent check time delay relay TD1. trol does not work.
  • Page 50 Trouble Remedy Engine slowly stopped and cannot be Check fuel level. restarted. Check fuel/hour meter for indication of shutdown. Check engine air and fuel filters (see Sections 8-3 and 8-7). See engine manual. Battery discharges between uses. Turn Engine Control switch off when unit is not running. Clean top of battery with baking soda and water solution;...
  • Page 51 Notes OM-242 702 Page 47...

  • Page 52: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator OM-242 702 Page 48...
  • Page 53 240 679-E OM-242 702 Page 49...

  • Page 54: Section 10 − Run-In Procedure

    SECTION 10 − RUN-IN PROCEDURE run_in1 2007−04 10-1. Wetstacking 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 55: Run-In Procedure Using Load Bank

    10-2. 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 equipment damage may occur.

  • Page 56: Run-In Procedure Using Resistance Grid

    10-3. Run-In Procedure Using Resistance Grid 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 equipment damage may occur.

  • Page 57: Section 11 − Generator Power Guidelines

    SECTION 11 − 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. 11-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
  • Page 58 11-3. 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 59 11-5. 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 60 11-7. 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 61 11-8. 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 62 11-10. 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- Fused Welding Utility al and national, state, and lo- Disconnect Electrical Generator...
  • Page 63 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten- sion cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts)

  • Page 64: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 907 427−3 907 427−8A Figure 12-1. Main Assembly OM-242 702 Page 60...
  • Page 65 50 51 907 427−10A OM-242 702 Page 61...
  • Page 66 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly ... 168829 Transducer, Current 1000a Module Max Open Loop ....
  • Page 67 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly (Continued) ....199505 Hose Assy, Oil Drain 32.000 Lg (Includes) ......
  • Page 68 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly (Continued) ....213462 Pad, Mtg Generator ..........
  • Page 69 Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 25 26 907 427-12A Figure 12-2. Panel, Front w/Components Item Dia. Part Mkgs. Description Quantity Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 90 ) .
  • Page 70 Item Dia. Part Mkgs. Description Quantity Figure 12-2. Panel, Front w/Components (Continued) ... . . 217680 Switch, Ignition 4 Position W/Out Handle ......
  • Page 71 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 242 269-B Figure 12-3. Control Panel Item Dia. Part Mkgs. Description Quantity Figure 12-3. Control Panel (Figure 12-1 Item 2) ..
  • Page 72 Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 907 427-13 Figure 12-4. Generator Item Dia. Part Mkgs. Description Quantity Figure 12-4. Generator (Figure 12-1 Item 63) ..ROTOR .
  • Page 73 Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 804 010−A Figure 12-5. Rectifier Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-5. Rectifier Assembly (Figure 12-1 Item 4) ....217082 Rectifier, Assembly (Includes) .
  • Page 74 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo- nents separately or as part of the associated wiring harness. Item Dia. Part Mkgs. Description Quantity Wiring Harnesses ....242270 Harness, Engine/Weld Mitsubishi (Includes) .
  • Page 75 Effective January 1, 2012 (Equipment with a serial number preface of MC or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
  • Page 76 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 2012 Miller Electric Mfg. Co. 2012−01...

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