Miller Electric Big Blue 500 PT, Big Blue 600 X manual Control Box Assembly − CC/CV Models

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803 846-D

				Figure 13-3. Control Box Assembly − CC/CV Models
Item		Dia.		Part	Description	Quantity
	No.	Mkgs.		No.	Description	Quantity
				Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1Item 111)

. . .	1 . . . F1, F2		. . *085 874 . .		FUSE, mintr cer slo-blo 10A 250V	. . . 2
. . .	2 . . . .	. . . . . .	. . .	046 432 . .	HOLDER, fuse mintr .250 x 1.250	. . . 2
. . . 3 . . . .		. . . . . .	. . .	201 077 . .	CONTROL BOX, lh	. . . 1
. . . 4 . . . .		. . . . . .	. . .	201 078 . .	CONTROL BOX, rh	. . . 1
. . . 5 . . . . CR8			. . .	197 325 . .	RELAY, encl 12vdc spst 70a 4pin flange mtg	. . . 1
. . . 6 . . . . CR1			. . .	090 104 . .	RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg	. . . 1
. . .	7 . Engine Controller			219 848 . .	MODULE, control governor	. . . 1
. . .	. . . . . . .	. LE3	. . .	204 702 . .	CORE, torodial .187 id x .375 od x .125 thk	. . . 1
. . . 8 . . . . CR6			. .	♦090104 . .	RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg	. . . 1
. . . 9 . . D10/C10 .				189 701 . .	DIODE/CAPACITOR BOARD	. . . 1
. . . 10 . . . .		CB10	. . .	190 374 . .	CIRCUIT BREAKER, Auto Reset 12vdc 40 Amp	. . . 1
. . . 11 . . . .		. . . . . .	. . .	201 079 . .	COVER, control box	. . . 1
. . . 12 . . . .		CR5	. . .	223 710 . .	RELAY, encl 12vdc dpst−no 25a 6pin flange	. . . 1
. . . 13 . . . .		PC7	. . ♦195 706 . .		MODULE, pull to idle, two output, 7 pin	. . . 1
. . . 14 . . . .		SR1	. . .	035 704 . .	RECTIFIER, integ 40A 800V	. . . 1
. . . 15 . . . .		CR4	. . ♦113 247 . .		RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg	. . . 1
. . . 16 . . . .		PC9	. . .	192 224 . .	CIRCUIT CARD ASSY, display	. . . 1

OM-4429 Page 74

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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