Miller Electric Big Blue 500 PT, Big Blue 600 X Run-In Procedure Using Resistance Grid, Manual

Page 62

11-3. Run-In Procedure Using Resistance Grid

Stop engine.

Do not touch hot exhaust pipe, engine parts, or load bank/grid.

6

Keep exhaust and pipe away

from flammables.

 

NOTICE − Do not perform run-

2in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

 

 

 

1

Resistance Grid

 

 

 

Use grid sized for generator rated

 

 

1

output.

 

 

Turn Off grid.

 

 

 

 

 

 

2

Welding Generator

 

 

 

Place A/V range switch in maxi-

 

 

 

mum position, A/V control in mini-

 

 

 

mum position, and Output Selector

 

 

 

switch (if present) in either DC

 

 

 

position.

 

 

 

3

Weld Cables

 

 

 

Connect grid to generator weld

 

 

 

output terminals using proper size

 

 

 

weld cables with correct connec-

 

 

 

tors (polarity is not important).

 

 

 

4

Voltmeter

 

 

 

5 Clamp-On Ammeter

 

 

 

Connect voltmeter and ammeter as

3

5

 

shown, if not provided on generator.

 

Start engine and run for several

 

 

 

 

 

 

minutes.

 

 

 

Set grid switches and then ad-

 

 

 

just generator A/V control so

 

 

 

load equals rated voltage and

4

 

 

current of the generator (see

 

 

nameplate, rating label, or the

 

 

 

 

 

 

specifications section in this

 

 

 

manual).

+

 

 

Check generator and meters after

 

 

first five minutes then every fifteen

 

 

 

minutes to be sure generator is

 

 

 

loaded properly.

 

 

 

NOTICE − Check oil level frequent-

 

 

 

ly during run-in; add oil if needed.

 

 

 

It is recommended to run the weld-

 

 

 

ing generator for two hours mini-

 

 

 

mum and up to four hours under

 

 

 

load. Place A/V control in minimum

 

 

 

position, then shut down grid to

 

 

 

remove load. Run engine several

 

 

 

minutes at no load.

 

 

 

 

Stop engine and let cool.

 

 

 

6

Engine Exhaust Pipe

Repeat procedure if wetstacking is present.

S-0684

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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 blessuresRisque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures 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 médicauxStd − Definitions− 50 h Std 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 Volt-Ampere Curves For CC Models VoltsTIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV Models100% Duty Cycle At 400 Amperes Fuel ConsumptionDuty Cycle And Overheating 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 ControlsExample Combination Remote Amperage Control Stick Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label 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 SupplementaryClose panel opening if no connections are made to generator Three-Phase Power ConnectionRear Of Panel Supplementary Protector CB2 Supplementary Protector CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 − Maintenance & Troubleshooting Maintenance LabelRoutine Maintenance Servicing Air Cleaner To clean air filterInspecting And Cleaning Optional Spark Arrestor Muffler Checking Generator BrushesTo replace primary fuel filter Servicing Fuel And Lubrication SystemsTo change oil and filter Overload Protection Troubleshooting Welding − CC ModelsWelding − CC/CV Models Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models Only 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 Welding Generator − RUN-IN ProcedureWetstacking From flammables Run-In Procedure Using Load BankKeep exhaust and pipe away 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 123 116 CV 112 − Parts List114 −7 115 CV 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 Support ServiceYour distributor also gives 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
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