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Miller BIG BLUE 500DX Owner's Manual
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Miller BIG BLUE 500DX Owner's Manual

Miller BIG BLUE 500DX Owner's Manual

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OWNER'S
IMPORTANT: Read and understand the entire contents of this manual, with
special emphasis
on the safety material throughout
installing, operating, or maintaining this equipment. This unit and these
instructions are for use only by persons trained and experienced in the safe
operation of welding equipment. Do not allow untrained persons to instaH,
operate, or maintain this unit. Contact your distributor if you do not fully
understand
these
instructions.
o
MANUAL
the manual, before
MILLER ELECTRIC Mfg. co.
A Miller Group Ltd.. Company
P.O. Box 1079
Appleton.
WI 54912 USA
Tel. 414-734-9821
PRINTED
IN USA

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Summary of Contents for Miller BIG BLUE 500DX

  • Page 1 A Miller Group Ltd.. Company installing, operating, or maintaining this equipment. This unit and these P.O. Box 1079 instructions are for use only by persons trained and experienced in the safe Appleton.
  • Page 2 Effective January 1, 1992 (Equipment with a serial number preface ot "KC" or newer) Thia limited warranty supsmed•a MILLER warr•nties and is exctusive wdh no other guarantees or warranties expressed Dt implied, UMTED WARRANTY the terms and below. MILLER Electric Accessory Kits Mtg.
  • Page 3 September 1992 FORM: S129 647B Use above FORM number when ordering extra manuals. SUPPLEMENTARY DATA For BIG BLUE'" 500DX Models The data contained in this supplement is either in addition to or takes exception to data appearing later in this manual.
  • Page 4 Add the following to Section 4-4. FUEL The fuel tank may be equipped with a fuel pan and drain hose (per NSPR 9777, if applicable). If fuel spills while filling tank, the fuel drains into the pan, through drain hose, and out base of unit. AMENDMENT TO SECTION 5 - AUXILIARY POWER...
  • Page 5 REV. FIELD æv. FIELD...
  • Page 6 scton AtS3) SB(SR2-POS) 1 3AtS3) 2tS3) IOAIRJ) 9A(R1) 23A(S3) REACTOR 2(S3) 33A'S3) ALT . BATT. WELD EXCITER STATOR STATOR ROTOR ST ARTER BATTERY BATTERY GND . Diagram 11-2. Wiring Diagram s 129 647 Page 4...
  • Page 7 ccc1L-3) (COIL 3tC01L-3) 374 (SRJI atC01L.3) 33AlC01 I Icon.-3) 32A {COIL - ' 27A(93) aamc01L--n 23AICOtL-2) accolL-2) 3 (COIL -a ) XC TER/STAtm '01B PL-2 GND . STUD 2'A(S3) 37A ($3) NEG. OUTPUT OUTPUT 19AIM3-PCS Wlring Diagram SD-154 S129 647 Page 5...
  • Page 9 FORM: OM-463Q June 16, 1992 ERRATA SHEET After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in this manual. AMENDMENT TO SECTION 5 - AUXILIARY POWER Amend Section 5-1. 120 VOLTS AC RECEPTACLES Up to 3 kVA/kWof 120volts ac60 Hz power is available at the 120 VOLTSAC duplex receptaclesfor oper ng either 60 or 50/60 Hz powertools, lights, etc.
  • Page 10 STATOR) RING) 21 n WELO STATOR) REACTOR PIS31 2(S3) ALT. BATt . 7'AtPeil WELD EXCITER STATOR STATOR ROTOR STARTER BATTERY BATTERY GND. Diagram 11-2. Wiring Diagram OM.463Q Page 2...
  • Page 11 ( COIL -3) IBCCB PL-2 STUC 27AtS3) '7BlS31 NEG. OUTPUT SR3-t•CG) POS . OUTPUT ' 9Atsa3•POSi Wiring Diagram No. SD-154 291 OM-463Q Page 3...
  • Page 12 OM-463Q Page 4...
  • Page 13 AMENDMENT TO SECTION 12 - PARTS LIST Amend Parts List as follows: Replaced Dia. Description Quantity Mkgs. With 43-62 151 969 SWITCH. pressure oil 4PSl . 153 299 ENDBELL, gen (consisting of) 47-23 O-RING, 2.859 ID x .139CS . 143 220 PANEL, front upper (Eff w/KC250438) 49-3 045 217...
  • Page 15 OM.463Q - 5/92 RECEIVING-HANDLING Use the following spaces to record the Model Designa- Before unpacking equipment, check carton for any dam- tion and Serial or Style Number of your unit. The infor- age that may have occurred during shipment. File any claims for loss or damage with the delivering carrier.
  • Page 16 Page No. Section SECTION 6 - EVALUATING AUXILIARY POWER REQUIREMENTS Auxiliary Power Generators 6-1. Load Evaluation 6-2. 6-3. Generator Capability Standby Power Connections 6-4. Diagram 6-1 . Standby Power Equipment And Connections 6-5. Auxiliary Power Extension Cord Selection SECTION 7 - OPERATOR CONTROLS Range Switch 7-1.
  • Page 17 Page No. Section SECTION 11 - ELECTRICAL DIAGRAMS Diagram 11-1. Circuit Diagram Diagram 11-2. Wiring Diagram SECTION 12 - PARTS LIST Figure 12-1. Main Assembly Figure 12-2. Bracket, Mtg Power Output Figure 12-3. Generator Figure 12-4. Panel, Front w/Components Figure 12-5. Switch, Range Optional Equipment LIST OF CHARTS AND TABLES...
  • Page 19 SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE welding or cutting, (and chipping) to protect the eyes INTRODUCTION 1-1. from radiant energy and flying metal. Replace cover We learn by experience. Learning safety through per- glass when broken, pitted, or spattered. See 1-3A.2. sonal experience, like a child touching a hot stove is Avoid oily or greasy clothing.
  • Page 20 ment as recommended in A6.0. Waterfilling just below atmospheres containing even minute amounts working level may substitute for inerting. trichloroethylene or perchloroethylene. A container with unknown contents should be cleaned C. Fire and Explosion Prevention (seepreceding paragraph). D oNOTdependonsenseof Causes offire and explosion are: combustibles reached smell or sight to determine if it is safe to weld or cut.
  • Page 21 outlet away from people and sources of ignition. Wipe Prohibited use. Never use a cylinder or its contents for with a clean lintless cloth. other than its intended use, NEVER as a support or roller. Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking area, and Locate or secure cylinders so they cannot be knocked that the regulatorinletand cylinder outlet match.
  • Page 22 Viewing the weld. Provide face shields for all persons 1-3. WELDING who will be looking directly at the weld. Comply with precautions in 1-1, 1-2, and this section. Others working in area. See that all persons are wearing Arc Welding, properly done, is a safe process, but a flash goggles.
  • Page 23 Welding power sources used with shielded electrically HOT by stray current may shock, possibly fa- metal arc welding (SMAW) and similar proc- tally. Do NOT GROUND to electrical conduit, orto a pipe esses may not be equippedwith welding power carrying ANY gas or flammable liquid such as oil or fuel. output on-off control devices.
  • Page 24 fromthe Compressed GasAssociation, 1235Jef- ANSI Standard Z49.2, FIRE PREVENTION ferson Davis Highway, Suite 501, Arlington, VA THE USE OF CUTTING AND WELDING PROC- ESSES obtainable from the American National 22202. Standards Institute, 1430 Broadway, New York, CSA Standard WI 17.2, CODE FOR SAFETY IN 10018.
  • Page 25 SECTION 3 - SPECIFICATIONS Specifications Table 3-1. Rated Max. Open- Single-Phase Welding Output Weight AC Auxiliary Circuit Max. Range Ampere Voltage Power 100% No Load Ranges C cle While Weldin Min.-80 3kVA/kW 70-130 400 Amperes 45 to 500 120 or 240 Volts AC 1898 lbs.
  • Page 26 Chart 3-2. Duty Cycle VOLT-AMPERE CURVES (Chart 3-1) 3-1 . RATED OUTPI,.JT 1200 1000 WELD OUTPUT The volt-ampere curves show the voltage and amper- age output capabilities of the welding generator at mini- mum and maximum of each coarse range. Curves of other settings fall between the curves shown Chart 3-1.
  • Page 27 SECTION 4 - INSTALLATION OR RELOCATION LOCATION (Figure 3-1) 4-1. • See Figure 4-1 for maximum allowable tilt for proper operation. A proper installation site should be selected for the weld • Check crankcase oil level with unit on a level ing generator if the unit is to provide dependable service surface.
  • Page 28 IMPORTANT: Fill fuel tank upto 1/2 in. (13 mm) from top EXHAUST EXTENSION INSTALLATION 4-2. with fresh fuel before starting engine the first time. Rust WARNING: ENGINE PARTS can cause and corrosion preventative was added to inside of fuel severe burns.
  • Page 29 4-6. EQUIPMENT GROUNDING TERMINAL (Fig- reduce output or cause unit overload due to ure 4-2) added resistance. GROUND Use weld cable with an insulation voltage rating equal to or greater than the maximum open-cir- cuit voltage (ocv) of the welding generator (see Table 3-1 for unit maximum ocv rating).
  • Page 30 tained and installed. To install the ether cylinder, pro- B. Weld Cable Preparation ceed as follows: Install electrode holder to cable following manu- facturer's instructions. Always use an insulated WARNING: IMPROPER HANDLING OR EX- POSURE TO ETHER can seriously harm your electrode holder to ensure operator safety.
  • Page 31 SECTION 5 - AUXILIARY POWER 120 VOLTS AC RECEPTACLE (Chart 5-1 And 5-1. Figure 7-1) POWER OUTPUT 120 VOLTS WARNING: ELECTRIC SHOCK kill; Upto 3 kVA/kWof 120 volts ac 60 Hz power is available MOVING PARTS can cause serious injury; IMPROPER AIRFLOW EXPOSURE...
  • Page 32 Chart 5-2. AC Power Curve For 120/240 Volts AC 7.5 KVA/KW AC POWER PLANT (Optional) 5-3. Terminals (No Weld Load Condition) (Chart 5-2 And Figure 5-1) WARNING: ELECTRIC SHOCK kill. • Do not touch live electrical parts. 11.5 K" • Keepjunction box coverin place while engine is running.
  • Page 33 INSTALLATION INSTRUCTIONS 5-4. TIONAL 240 VOLTS DUPLEX RECEPTACLE Upper Riaht Corner Of Unit (Figures 5-2 And 5-3) Terminal Case Block A voltage changeover terminal block, located behind the right side door, provides reconnection capability for 240 volts ac. Although the capability for 240 volts ac is pre- Front Pane sent, an optional kit must be purchased if 240 volts is de-...
  • Page 34 SECTION 6 - EVALUATING AUXILIARY POWER REQUIREMENTS frames must be connected. If the generator is 6-1. AUXILIARY POWER GENERATORS supplying a permanent installation or some load Introduction that does not meet the mounting or receptacle The auxiliary power generated from this unit is most connection exclusion, the generator frame and commonly used in industrial, small business, and resi-...
  • Page 35 Table 6-1 . Power Requirements* APPROXIMATE APPROXIMATE APPROXIMATE APPROXIMATE FARM EQUIPMENT RATING IN DUST RIAL MOTORS RATING STARTING WATTS RUNNING WATTS STARTING WATTS RUNNING WATTS 1000 '000 Split Phase Stock Tank De-lcer 1/4 Hp 1650 Grain Cleaner 1/6 Hp 1225 3400 1 ooo 1600...
  • Page 36 Single-Phase Induction Motor Starting Table 6-2. Running Load Requirements KVA/HP Requirements The total running load applied to the generator is calcu- lated by adding up all the individual loads. Some equip- Motor Start KVA/HP ment is rated in amperes, others in watts. The require- Code Letter ments for most equipment...
  • Page 37 IMPORTANT: Double-pole, double-throw transfer ond-maximum-time rule should be applied to all motor- switch rating must be the same as or greater than the starting situations to prevent damage to the start wind- main overcurrent protection. ing. If 90% of rated voltage is present across the mo- tor terminals when running under load, then it is...
  • Page 38 cords of adequate amperage capacity, and use the fol- AUXILIARY POWER EXTENSION CORD 6-5. lowingTables6-3 and 6-4 to selectconductorsize ac- SELECTION (Tables 6-3 And 6-4) cordingto cordlength.Usethe shortestcordspossible because excessive cord lengths may reduce output or Extension cords may be necessary if power is supplied cause unit overload due to added resistance.
  • Page 39 Table 6-4. Cord Lengths For 240 Volt Loads Maximum Allowable Cord Length In Feet (Meters) For Conductor Size (AWG)* Current Load Amperes Watts 1200 (137) (84) (61) (213) 1680 (91) (61) (38) (244) (152) 2400 (168) (107) (69) (38) (31) 3600 (46) (23)
  • Page 40 STOP CONTROL (Figure 7-1) 7-1. RANGE SWITCH (Figure 7-1) 7-4. AMPERE RANGES PULL STOP ENGINE DO NOT SWITCH UNDER LOAD The PULL OUT TO STOP ENGINE control, when pulled The Range switch provides five coarse amperage fully out, cuts off the flow of fuel at the fuel injection ranges.
  • Page 41 measurements. These meters are internally connected 7-11. TACHOMETER (Optional) to the output terminals. The voltmeter indicates the volt- age at the output terminals, but not necessarily The Tachometer, located on the front panel, registers actual voltage at the welding arc (due to cable resis- engine speed from O(zero) to 3000 rpm.
  • Page 42 SECTION 8 - SEQUENCE OF OPERATION SHIELDED METAL ARC WELDING (SMAW) WARNING: ELECTRIC SHOCK kill; 8-1 . MOVING PARTS cause serious injury; WARNING: Read and follow safety informa- IMPROPER AIRFLOW AND EXPOSURE tion at beginning of entire Section 8 before ENVIRONMENT can damage internal...
  • Page 43 CAUTION: ETHER INJECTION WHILE EN- 8-3. STARTING ENGINE GINE IS RUNNING can cause engine dam- IMPORTANT: Read entire engine Owner's Manual age. (Deutz F3L-912 engine) before operating engine. • Do not actuate ETHER STARTING AID while engine is running. Engine Prestart Checks DepressSTARTbuttonand ETHERSTARTING Oil Level AID switch, if applicable, at same time.
  • Page 44 Table 9-1. Maintenance Schedule Frequency* Maintenance Every day. Check fuel and oil levels (see Sections 4-4, 4-5, and engine Owner's Manual, Deutz F3L-912 engine). Every 40 hours. Empty air cleaner dust cap (see Section 9-2). Every 100 to 150 hours. Changeoil andfilter (seeengineOwner'sManual,DeutzF3L-912engine).
  • Page 45 Table 9-2. Air Cleaner Service Reinstall element. 1. Stop engine. 5. Wipe out element chamber Follow with clean, damp cloth B. Replace cover. 2. Wipe off cover before These 6. Inspect new element and all opening air cleaner. Easy gaskets for shipping damage before use. Steps: Remove cover.
  • Page 46 Sludge Drain Plug Use enough ventilation to keep battery gases from building up during and for several hours A sludge drain plug is provided to drain off sediment from after battery charging. the fuel tank. Once a week, drain the sludge into a metal Turn battery charger off before making con- container.
  • Page 47 BRUSHES AND SLIP RINGS (Figure 9-2) 9-6. ENGINE SPEED ADJUSTMENT (Figure 9-1) 9-7. WARNING: ELECTRIC SHOCK can kilt This engine was shipped fully adjusted and ready for • Do not touch live electrical parts. operation. If an engine speed adjustment becomes nec- essary, proceed as follows: •...
  • Page 48 Run-In Procedure using Load Bank (Diagram MOVING PARTS can cause severe injury. 9-1) • Keep away from moving parts such as fans, belts, and rotors. WARNING: Read and follow safety informa- tion at beginning of entire Section 9-8 be- ENGINE PARTS cause severe...
  • Page 49 For example, if rated generator output is 350 am- After running engine under load for at least one peres, 40 volts at 100% duty cycle, adjust hour, remove load by shutting down load bank switches until values indicated by meters equals Allow engine to idle for approximately three min- rated generator output.
  • Page 50 Allow engine to idle for approximately three min- 15 minutes to allow particles in fuel to settle to prevent utes to permit internal engine temperatures atomizer plugging. equalize. 9-10. SIDE OIL DRAIN (Optional) Stop engine, and disconnect weld cables. This welding generator can be equipped with an oil drain Allow exhaust system to cool.
  • Page 51 Valve should reset itself a few minutes after en- Using Figure 9-1 , locate and loosen linkage lock gine stops. Loosen lock nut on valve adjustment nut closest to end of linkage until nut is near end of screw (see Figure 9-3), and rotate screw one turn. threads.
  • Page 52 10-3. OVERLOAD PROTECTION FOR OPTIONAL Replace junction box cover. Close and secure left 7.5 KVA/KW POWER PLANT (Figure 5-1) side door. WARNING: ELECTRIC SHOCK can kill. TROUBLESHOOTING (Table 10-1) 10-4. • Do not touch live electrical parts. WARNING: ELECTRIC SHOCK kill.
  • Page 53 Table 10-1. Troubleshooting REMEDY PROBABLE CAUSE TROUBLE Inspectthe electrical s ystem(seeSection9-1A Engine fails to start. Battery. and B). Testthe battery,and chargeit if neces- sary (see Section9-5).If the batterydoes not charge, replace the battery. Jumpstartthe engineaccordingto Section 10-2. Place S3 in proper position (see Section 7-1). Range switch S3 is between No weld output.
  • Page 54 NOTES OM-463 Page 36...
  • Page 55 SECTION 11 - ELECTRICAL DIAGRAMS REV. REV. FIELD OM.463 Paae 37...
  • Page 56 IA(WELO 13AtS3) 21AtWELO STATOR) 23A(SJ) REACTOR etSJ) 3(S3) STATOR) 2(S3) .49A(Pl-l) BATT WELD EXCI STAT CR STATOR STARTER BATTERY ROTOR BATTERY GND . Diagram 11-2. Wiring Diagram OM-463 Page 38...
  • Page 57 (COIL-I) (COIL -3) 3(C01L-3) 3(CC1'.-l) 17E(SR3) 33A COIL-I EQUIP GND . 32A (COIL-I 5B t SR2-POS) (COIL-31 g (sm-pos} SOA(EXCITERJ (93) 7Å(R2) (93) SA(SLiP RING) 2(C01L-m t SR2-AC) 8A(SLIP RING) 3tC01L-2) 3B (Ttl-ei PL-2 71 ACSTARTER 'OB(STARTER "(EXCITER) I A (EXCITECO 27A(S3) '7B{S3) 19k IPOS.
  • Page 58 SECTION 12 - PARTS LIST Fig 12-2 - 101 Fig 12-4 Figure 12-1. Main Assembly OM-463 Page 40...
  • Page 59 Fig 12-3 - SD.04B 455.P OM-463 Page 41...
  • Page 60 Dia. Part Item Quantity Description Mkgs. Figure 12-1. Main Assembly PLUG, protective .640sq TANK, fuel (consisting of) 115 ooo FITTING, pipe brs elb st 1/8NPT FITTING, brs barbed M 3/16tbg x 1/8NPT CLAMP, hose .375-.450 HOSE, SAE .187 ID x .410 OD (order by ft) 134 834 STRIP, rbr adh back .125 x 1,000 x 27.500 VALVE, shut-off fuel...
  • Page 61 Part Item Quantity Description Mkgs. Figure 12-1. Main Assembly (Continued) HOSE, air cleaner . 48 CLAMP, hose 2.062-3.000clp AIR CLEANER, intake (consisting of) . 50 BAND, mtg air cleaner . 51 ELEMENT *020 NOT, wg . 53 CLAMP ASSEMBLY . 54 CAP, dust .
  • Page 62 Part Item Dia. Quantity Description Mkgs. Figure 12-1. Main Assembly (Continued) REACTOR 083 030 STUD, brs .250-20 x 1.750 grounding NUT, brs hex .250-20 jam hvy grounding KNOB, ball PANEL, front w/components Fig 12-4 BRACKET, mtg pwr output Fig 12-2 UPRIGHT, base front +048...
  • Page 63 part Item Dia. Quantity Description Mkgs. Figure 12-2. Bracket, Mtg Power Output (Fig 12-1 Item 101) BRACKET, mtg term pwr output BRACKET,mtg term pwr output (used w/polarity switch) . +088 TERMINAL, pwr output black (consisting of) TERMINAL, pwr output red (consisting of) 039 047 NUT, sti hex full fnsh .500-13 601 879...
  • Page 64 OM-463 Page 46...
  • Page 65 Item Dia. part Quantity Description Mkgs. Figure 12-3. Generator (Fig 12-1 Item 70) HOSE, nprn slit bk .156 ID x 343 OD (order by ft) 603 107 BAFFLE, air rectifier BAFFLE, air diodes . INSULATOR 106 440 BUS BAR, rectifier DIODE ASSEMBLY, reverse polarity (consisting of) 106 427 CAPACITOR,...
  • Page 66 Fig 12-5 SC-048 S47.G Figure 12-4. Panel, Front w/Components 0M-463 Page 48...
  • Page 67 Item Dia. Part Quantity Description Mkgs. Figure 12-4. Panel, Front w Components (Fig 12-1 Item 100) NAMEPLATE, (order by model and serial number) DIODE, rect 3A 1000V SP 045 217 PANEL, front upper SWITCH, range (Fig 12-5) RHEOSTAT, WW 300W 34 ohm RECEPTACLE, dx grd 2P2W 15A 125V CAP, P &...
  • Page 68 Part Item Quantity Description Figure 12-5. Switch, Range (Fig 12-4 Item 4) BRACKET, mtg switch (consisting 00 114 235 SPRING, ext .312 OD x .042 wire x 1.875pId . 010 671 LOCATOR, quadrant CONTACT BOARD, (consisting of) 048 536 CONTACT, movable (consisting of) SPRING, pressure .
  • Page 69 Dia. part Quantity Description Mkgs. Optional Equipment (consisting of) . RCGD-40 REMOTE CONTROL FACILITIES, RECEPTACLE, twik grd 2P3W 15A 125V SWITCH, tgi SPDT 15A 125V 011 609 CONNECTOR, blk 30A 45deg FA-I FLAME ARRESTOR FUEL STARTING AID, diesel (consisting of) STARTING 034 074 SWITCH, tgi SPST MC 3A 250V...