Miller Electric Big Blue 500 PT Fumes and Gases can be hazardous, ARC Rays can burn eyes and skin

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FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

DKeep your head out of the fumes. Do not breathe the fumes.

DIf inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.

DIf ventilation is poor, wear an approved air-supplied respirator.

DRead and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

DWork in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch- person nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breath- ing air is safe.

DDo not weld in locations near degreasing, cleaning, or spraying op- erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

DDo not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

DAlways ventilate confined spaces or use ap- proved air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

DWear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

DWear approved safety glasses with side shields under your helmet.

DUse protective screens or barriers to protect others from flash, glare, and sparks; warn others not to watch the arc.

DWear protective clothing made from durable, flame-resistant mate- rial (leather, heavy cotton, or wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece,

and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

DRemove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

DDo not weld where flying sparks can strike flammable material.

DProtect yourself and others from flying sparks and hot metal.

DBe alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

DWatch for fire, and keep a fire extinguisher nearby.

DBe aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

DDo not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards).

DDo not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline).

DConnect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire haz- ards.

DDo not use welder to thaw frozen pipes.

DRemove stick electrode from holder or cut off welding wire at contact tip when not in use.

DWear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

DRemove any combustibles, such as a butane lighter or matches, from your person before doing any welding.

DAfter completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.

DUse only correct fuses or circuit breakers. Do not oversize or by- pass them.

DFollow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.

NOISE can damage hearing.

Noise from some processes or equipment can dam- age hearing.

DWear approved ear protection if noise level is high.

MAGNETIC FIELDS can affect Implanted

Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

DImplanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pres- sure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

DProtect compressed gas cylinders from excessive heat, mechani- cal shocks, physical damage, slag, open flames, sparks, and arcs.

DInstall cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.

DKeep cylinders away from any welding or other electrical circuits.

DNever drape a welding torch over a gas cylinder.

DNever allow a welding electrode to touch any cylinder.

DNever weld on a pressurized cylinder — explosion will result.

DUse only correct shielding gas cylinders, regulators, hoses, and fit- tings designed for the specific application; maintain them and associated parts in good condition.

DTurn face away from valve outlet when opening cylinder valve.

DKeep protective cap in place over valve except when cylinder is in use or connected for use.

DUse the right equipment, correct procedures, and sufficient num- ber of persons to lift and move cylinders.

DRead and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.

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Contents File Engine Drive ProcessesDescription Visit our website at OM-44292216 138H 2007−05From Miller to You Table of Contents − Maintenance & 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 blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque 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− Definitions − 50 h StdStd Manufacturer’s Rating Labels CC ModelsSymbols And Definitions Some symbols are found only on CE products− Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models VoltsTIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Duty Cycle And Overheating100% Duty Cycle At 400 Amperes 12 kVA/kW Single-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 20 kVA/kW Three-Phase AC Output No Weld LoadLocation/Airflow Clearance − InstallationInstalling Welding Generator Grounding1Using Lifting Eye Mounting Welding Generator Installing Exhaust Pipe Stop engine and let coolActivating The Dry Charge Battery If Applicable Connecting The BatteryFuel Coolant Recovery TankEngine Prestart Checks OilMIG and Fcaw Welding Connecting To Weld Output TerminalsStick and TIG Welding Stop engine150 ft 200 ft 250 ft Connecting to WeldSelecting Weld Cable Sizes 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 Gauges And Meters Engine Starting ControlsTo Start Weld ControlsRemote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample 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 TIGAt least once a month, run en − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles If a SupplementaryThree-Phase Power Connection Rear Of PanelClose panel opening if no connections are made to generator Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Supplementary 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 BrushesServicing Fuel And Lubrication Systems To change oil and filterTo replace primary fuel filter Overload Protection Troubleshooting Welding − CC ModelsWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine Factory Authorized Service Agent Check engine wiring harness plug connectionsGine Control switch S1 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 − RUN-IN Procedure WetstackingWelding Generator Run-In Procedure Using Load Bank Keep exhaust and pipe awayFrom 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 114 −7 115 CV123 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 Service Your distributor also givesSupport 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