Miller Electric Big Blue 500 PT, Big Blue 600 X manual Process/Contactor Switch On CC/CV Models

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7-3. Process/Contactor Switch On CC/CV Models

1 Process/Contactor Switch

! Weld output terminals are ener- gized when Process/Contactor switch is in an Weld Terminals Always On position and the en- gine is running.

!

1

DC voltage is still present at the weld terminals when Process/ Contactor switch is in the Re- mote On/Off Switch Required − Stick position and the engine is running.

Use switch to select weld process and weld output on/off control (see table be- low and Section 7-4).

Place switch in Remote On/Off Switch Required positions to turn weld output on and off with a device connected to the remote 14 receptacle.

Place switch in Weld Terminals Always On positions for weld output to be on whenever the engine is running.

Use Stick position for air carbon arc (CAC-A) cutting and gouging.

When switch is in a Stick position, the arc drive (dig) circuit provides addition- al amperage during low voltage (short arc length conditions) to prevent “stick- ing” electrodes.

The arc drive (dig) circuit is disabled when switch is in MIG or TIG positions.

.

.

Place switch in Weld Terminals Al- ways On - Stick position when us- ing optional three-phase generator (see Section 8-2).

The engine auto idle option does not work in the Remote On/Off Switch Required-TIG mode.

Process/Contactor Switch Settings

Switch Setting

Process

Output On/Off Control

Engine Auto Idle (Optional)

 

 

 

 

Remote On/Off Switch Re-

GTAW With HF Unit, Pulsing

 

 

quired − TIG, HF Required

At Remote 14 Receptacle

Not Active

Device, Or Remote Control

Or Scratch Start TIG

 

 

 

 

 

 

 

 

 

Remote On/Off Switch

Stick (SMAW) With Remote On/Off

At Remote 14 Receptacle

Active

Required − Stick

 

 

 

 

 

 

 

Remote On/Off Switch

 

 

 

Required − CV Feeder

MIG (GMAW)

At Remote 14 Receptacle

Active

Using Remote

 

 

 

 

 

 

 

Weld Terminals Always On −

MIG (GMAW)

Electrode Hot

Active

Wire

 

 

 

 

 

 

 

Weld Terminals Always On −

Stick (SMAW),

 

 

Air Carbon Arc (CAC-A) Cutting

Electrode Hot

Active

Stick

And Gouging

 

 

 

 

 

 

 

 

 

Weld Terminals Always On −

TIG Scratch Start (GTAW)

Electrode Hot

Active

TIG, Scratch Start

 

 

 

 

 

 

 

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Contents Processes DescriptionFile Engine Drive Visit our website at OM-44292216 138H 2007−05From Miller to You Table of Contents − Maintenance & Troubleshooting Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiquesDES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion 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 LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF 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 productsWeld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models VoltsStick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsDuty Cycle And Overheating Fuel Consumption100% Duty Cycle At 400 Amperes AC Generator Power Curve Optional Three-Phase Generator Curves12 kVA/kW Single-Phase AC Output No Weld Load 20 kVA/kW Three-Phase AC Output No Weld Load− Installation Installing Welding GeneratorLocation/Airflow Clearance Grounding1Using Lifting Eye Mounting Welding Generator Installing Exhaust Pipe Stop engine and let coolActivating The Dry Charge Battery If Applicable Connecting The BatteryCoolant Recovery Tank Engine Prestart ChecksFuel OilConnecting To Weld Output Terminals Stick and TIG WeldingMIG and Fcaw Welding Stop engineConnecting to Weld Selecting Weld Cable Sizes150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mConnecting To Remote 14 Receptacle RC14 On CC/CV Models SocketOM-4429 − Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionEngine Starting Controls To StartEngine Gauges And Meters Weld ControlsWeld Control/Arc Condition Information Label Remote Amperage Control On CC Models OptionalExample Combination Remote Amperage Control Stick OM-4429 − 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 TIG− Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesAt least once a month, run en If a SupplementaryRear Of Panel Three-Phase Power ConnectionClose panel opening if no connections are made to generator 240 V 15 a AC South African Receptacle RC1 Optional Generator Power ReceptaclesSupplementary Protector CB2 Supplementary Protector CB3 − Maintenance & Troubleshooting Maintenance LabelRoutine Maintenance Servicing Air Cleaner To clean air filterInspecting And Cleaning Optional Spark Arrestor Muffler Checking Generator BrushesTo change oil and filter Servicing Fuel And Lubrication SystemsTo replace primary fuel filter Overload Protection Troubleshooting Welding − CC ModelsWelding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Only Standard Generator PowerEngine Check engine wiring harness plug connections Gine Control switch S1Factory Authorized Service Agent Engine cranks but does not start Check fuel levelStart Your Professional Welding Career Now − Electrical Diagrams Circuit Diagram For CC Welding Generator223 525-B Circuit Diagram For CC/CV Welding Generator 223 524-B Wetstacking − RUN-IN ProcedureWelding Generator Keep exhaust and pipe away Run-In Procedure Using Load BankFrom flammables Run-In Procedure Using Resistance Grid Specifications section in thisJust generator A/V control so Manual− Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Electrically Bond GeneratorGrounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated in electrical codes Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible 114 −7 115 CV − Parts List123 116 CV 112 2831 124 88 −6 6059 58 Dia Part Description Quantity Dia Part Description Quantity Mkgs Figures 13-2 111123 212 Control Box Assembly − CC Models Control Box Assembly − CC Models -1Item Engine ControllerControl Box Assembly − CC/CV Models 134 Panel, Front w/Components − CC Models 3634208278 Panel, Front w/Components − CC/CV Models Panel, Front w/Components − CC/CV Models -1ItemCB1 201 Supplementary PROTECTOR, man reset 2P 20 A, 250VAC Hardware is common 32 31 30053 BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X Main Rectifier Assembly Wiring Harnesses 215207 Your distributor also gives ServiceSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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