Miller Electric 600 X, 500D manual PLG3

Page 94

Item

Dia.

 

Part

Description

Quantity

No.

Mkgs.

 

No.

 

 

Figure 15-2. Control Box Assembly − CC Models (Continued)

 

 

 

 

 

 

 

. . . . . . . . . .

. . . . . .

. . .

215 013 . .

HARNESS, unit weld control (consisting of)

. . . . . 1

. . . . . . . . . .

PLG3

. . .

158 465 . . .

. CONN, rect univ 084 12p/s 3row plug cable lkg

. . . . . 1

. . . . . . . . . .

. . . . . .

. . .

187 654 . . .

. SEAL, wire univ 12p/s 3row

. . . . . 1

. . . . . . . . . .

PLG6

. . . .

114 063 . . .

. CONN, rect univ 084 4p/s 1row plug cable lkg

. . . . . 1

. . . . . . . . . .

. . . . . .

. . .

192 309 . . .

. CLIP, snap in .630 bundle .250 hole .248 thk

. . . . . 2

. . . 12 . . . .

. . . . . .

. . .

177 136 . .

CLAMP, capacitor 1.375dia

. . . . . 1

. . . 13 . . . .

. C9 .

. . . .

087 110 . .

CAPACITOR, elctlt 240uf 200VDC

. . . . . 1

. . . 14 . . . .

. R6 .

. . .

141 424 . .

RESISTOR, ww fxd 30 w 25 ohm faston te

. . . . . 1

. . . 15 . . . .

PC7

. . ♦195 706 . .

MODULE, pull to idle, two output, 7 pin

. . . . . 1

. . . 16 . . . .

CR4

. . ♦113 247 . .

RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg

. . . . . 1

. . . 17 . . . .

CR6

. . ♦090 104 . .

RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg

. . . . . 1

. . . 18 . . . .

CR3 . . .

090 104 . .

RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg

. . . . . 1

. . . . . . . . . .

. . . . . .

. . .

215 660 . .

HARNESS, engine control (Deutz F4L2011 engine) (consisting of)

. . . . 1

. . . 19 . . .

D1/C1

. .

189 701 . . .

. DIODE/CAPACITOR BOARD

. . . . . 1

. . . 20 . . . .

CB10

. . .

190 374 . . .

. CIRCUIT BREAKER, auto reset 12VDC 40A

. . . . . 1

. . . . . . . . . .

. . . . . .

. . .

148 850 . . .

. SOCKET, relay 5 pin

. . . . . 2

. . . . . . . . . .

PLG4

. . . .

114 062 . . .

. CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg

. . . . . 1

. . . . . . . . . .

. . . . . .

. . .

173 916 . . .

. HOUSING, contact 10-pole

. . . . . 1

. . . 21 . . . .

CR1

. . .

214 876 . . .

. RELAY, encl 6vdc spst 35a/14vdc 5 pin

. . . . . 1

. . . 22 . . . .

CB14

. . ♦205 927 . . .

. CIRCUIT BREAKER, auto reset 12vdc 12 amp

. . . . . 1

. . . . . . . . . .

. . . . . .

. . .

205 931 . .

HARNESS, engine control (Deutz F3L912 engine) (consisting of)

. . . . . 1

. . . 19 . . .

D8/C8

. .

189 701 . . .

. DIODE/CAPACITOR BOARD

. . . . . 1

. . . 20 . . . .

CB10

. . .

190 374 . . .

. CIRCUIT BREAKER, auto reset 12VDC 40A

. . . . . 1

. . . . . . . . . .

. . . . . .

. . .

148 850 . . .

. SOCKET, relay 5 pin

. . . . . 2

. . . . . . . . . .

PLG4

. . . .

114 062 . . .

. CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg

. . . . . 1

. . . 21 . . . .

CR1

. . .

214 876 . . .

. RELAY, encl 6vdc spst 35a/14vdc 5 pin

. . . . . 1

. . . 22 . . . .

CB14

. . .

205 927 . . .

. CIRCUIT BREAKER, auto reset 12vdc 12 amp

. . . . . 1

. . . 23 . . . .

CR8

. . ♦197 325 . .

RELAY, encl 12vdc spst 70a 4pin flange mtg

. . . . . 1

. . . 24 . . . .

TD1

. . .

214 928 . .

TIMER, delay on make/break open 30 sec 12vdc

. . . . . 1

. . . 25 . . . .

CR9

. . .

090 104 . .

RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg

. . . . . 1

. . . . . . . . . .

. . . . . .

. . .

235 251 . .

HARNESS, fuel shutdown solenoid (consisting of)

. . . . . 1

. . . 26 . . . .

. R7 .

. . .

235 250 . . .

. RESISTOR, hsc 30 w 3 ohm

. . . . . 1

. . . . . . . . . .

. . . . . .

. . .

148 850 . . .

. SOCKET, relay 5 pin

. . . . . 1

♦Optional

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4428 Page 90

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Contents Description OM-4428215 932KProcesses File Engine DriveFrom Miller to You Table of Contents Troubleshooting Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosionEngine Hazards Compressed Air HazardsFire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation Indique des instructions spécifiquesLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu DES Organes Mobiles peuvent pro voquer des blessures’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures ’EMPLOI Excessif peutInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité En ce qui concerne les implants médicaux− 50 h Std − DefinitionsStd Manufacturer’s Rating Labels CC ModelsSymbols And Definitions Some symbols are found only on CE productsDimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Lifting Eye Weight RatingVolt-Ampere Curves For CC Models VoltsTIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV ModelsCurve shows typical fuel use under weld or power loads Fuel ConsumptionDuty Cycle And Overheating AC Generator Power Curve100% Duty Cycle At 500 Amperes 12 kVA/kW Single-Phase AC Output No Weld Load Optional Three-Phase Generator Curves20 kVA/kW Three-Phase AC Output No Weld Load Location/Airflow Clearance − InstallationInstalling Welding Generator Grounding1Using Lifting Eye Mounting Welding Generator After installing cylinder, wait at Installing Exhaust PipeStop engine and let cool Activating The Dry Charge Battery If Applicable Connecting The BatteryDeutz F3L912 Engine Engine Prestart ChecksDeutz F4L2011 Engine FuelStick and TIG Welding Connecting To Weld Output TerminalsCorrect Installation MIG and Fcaw Welding45 m 60 m 70 m 90 m 105 m 120 m Connecting to WeldSelecting Weld Cable Sizes Output terminalsConnecting To Remote 14 Receptacle RC14 On CC/CV Models Socket− Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionEngine Gauges And Meters Engine Starting ControlsTo Start Weld ControlsWeld Control/Arc Condition Information Label Remote Amperage Control On CC Models OptionalExample Combination Remote Amperage Control Stick Work like a Pro − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionVoltage/Amperage Adjust Switch And Remote 14 Receptacle 14 AC/DC Voltmeter OptionalProcess/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIGAt least once a month, run en − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles If a SupplementaryConnections Rear Of PanelClose Are made Generator240 V 15 a AC South African Receptacle RC1 Optional Generator Power Receptacles Standard ModelsSupplementary Protector CB2 Supplementary Protector CB3 Generator Power Receptacles Export Models Generator power is not affected by weld output− Maintenance Deutz F4L2011−POWERED Units Maintenance Label Deutz F4L2011-Powered UnitsRoutine Maintenance Deutz F4L2011-Powered Units Checking Generator Brushes Servicing Air Cleaner Deutz F4L2011-Powered Units To clean air filterBlow out cleanout hole. If nothing Spark Arrestor Muffler Cleanout PlugCovering cleanout hole Reinstall cleanout plug Tools Needed 3/8Do not set engine speed higher than specified Adjusting Engine Speed Deutz F4L2011-Powered UnitsStandard Models Models With Automatic Idle OptionalTo replace primary fuel filter To change oil and filterTo drain water from fuel system To replace secondary fuel filterOverload Protection Deutz F4L2011-Powered Units When a supplementary protector− Maintenance Deutz F3L912−POWERED Units Maintenance Label Deutz F3L912-Powered UnitsRoutine Maintenance Deutz F3L912-Powered Units Checking Generator Brushes See note above before cleaning. Re Ment is not covered by the warrantyClean or replace primary element if dirty CleaningsSpark Arrestor Muffler Cleanout Plug Adjusting Engine Speed Deutz F3L912-Powered Units To change oil and filter Overload Protection Deutz F3L912-Powered Units Troubleshooting − TroubleshootingWelding − CC Models Welding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine − Electrical Diagrams 215 221-E OM-4428 235 275-A OM-4428 215 806-E OM-4428 235 276-A OM-4428 215 807-D OM-4428 215 808-D Wetstacking − RUN-IN ProcedureWelding Generator Keep exhaust and pipe away Run-In Procedure Using Load BankFrom flammables Just generator A/V control so Run-In Procedure Using Resistance GridSpecifications section in this ManualGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Electrically Bond GeneratorUse ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Parts List CC CC Models Only CV CC/CV Models OnlyDeutz F4L2011 en Dia Part Description Quantity Dia Part Description Quantity Mkgs CC191 Control Box Assembly − CC Models PLG3 Control Box Assembly − CC/CV Models 193 SWITCH, rotary 6 position gold contacts Panel, Front w/Components − CC Models GFCI1 Temp Panel, Front w/Components − CC/CV Models Panel, Front w/Components − CC/CV Models -1ItemPC6 192 PC4, PC5 189 Hardware is common 2827602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Main Rectifier Assembly -1ItemPage Your distributor also gives ServiceSupport For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s

500D, 600 X specifications

Miller Electric is a well-known name in the welding and fabrication industry, and their 600 X,500D model represents a blend of innovative technology and robust performance. This advanced multiprocess welder is designed for both professionals and serious hobbyists, reflecting Miller's commitment to quality and reliability.

The Miller Electric 600 X,500D offers a powerful output with a maximum capability of 600 amps, making it an ideal choice for heavy-duty applications, including construction, shipbuilding, and industrial fabrication. One of the standout features of this welder is its versatility. It is capable of MIG, TIG, stick, and Flux-Cored welding processes, allowing users to tackle a wide array of welding tasks with ease.

The design of the 600 X,500D incorporates Miller's Auto-Set technology, which simplifies the welding process by automatically adjusting the machine settings based on the material thickness and type. This feature is particularly valuable for welders who may not have extensive experience, as it reduces the need for manual adjustments and potential errors.

Another notable technology included in this model is the Digital MIG control, which enhances arc stability and offers precise control of the weld. This leads to improved bead appearance and overall weld quality. Additionally, the welder supports advanced synergy control, enabling users to find the ideal settings for various materials and thicknesses quickly.

The 600 X,500D also features a robust construction designed to withstand the rigors of demanding job sites. Its rugged design is complemented by a user-friendly interface, complete with a bright digital display that allows for easy monitoring of settings and performance. The unit is also equipped with a built-in thermal overload protection system, ensuring that it operates safely even during extensive use.

Weight and portability are also important aspects of the 600 X,500D, making it easier for operators to transport the unit between job sites. The built-in handle and durable wheels enhance maneuverability, which is crucial for professionals who need a reliable welder on the go.

In summary, the Miller Electric 600 X,500D is a versatile and powerful multiprocess welder designed to meet the needs of demanding users. With features like Auto-Set technology, Digital MIG control, and a rugged build, it stands out as a top choice for achieving high-quality welds in various applications. The combination of advanced technologies and user-friendly design solidifies its reputation as an essential tool for professionals in the welding industry.
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