Miller Electric Big Blue 500 PT, Big Blue 600 X manual 215207

Page 88

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215207 . .

Harness, Unit Weld Control CV (Includes)

1

. . . . . . . . . . PLG6

. . . .

114063 . .

Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg

1

. . . . . . . . . . . . . . . .

. . . .

193184 . .

Conn, Rect Cinch 30 Pin

1

. . . . . . . . . . . . . . . .

. . . .

147992 . .

Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg

1

. . . . . . . . . . PLG3

. . . .

158465 . .

Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg

1

. . . . . . . . . . . . . . . .

. . . .

187654 . .

Seal, Wire Univ 12p/S 3row

1

. . . . . . . . . . . . . . . .

. . . .

196602 . .

Plug, Cavity 18,30 Position Cinch Connector

7

. . . . . . . . . . . . . . . .

. . . .

215377 . .

Harness, Control Box, CC/CV (Includes)

1

. . . . . . . CB11, 12, 13

139266 . .

Supplementary Protector,Man Reset 1p 15a 250vac

3

. . . . . . . . . . SR1

. . . . 035704 . .

Rectifier, Integ Bridge 40. Amp 800v

1

. . . . . . . . . . . . . . . .

. . . .

148850 . .

Socket, Relay 5 Pin

1

. . . . . . . . . . RC4 . . . . 047483 . .

Conn, Rect Univ 084 15p/S 3row Rcpt Cable/Panel Lkg

1

. . . . . . . . . . RC3 . . . . 158466 . .

Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg

1

. . . . . . . . . . RC1

. . . . 135133 . .

Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg

1

. . . . . . . . . . . . . . . .

. . . .

150316 . .

Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg

6

. . . . . . . . . . . S6 .

. . . .

193234 . .

Switch, Rotary 6 Posn Gold Contacts

1

. . . . . . . . . . . . . . . .

. . . .

021467 . .

Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term

1

. . . . . . . . . . . S5 .

. . . .

011609 . .

Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr

1

. . . . . . . . . D1/C1

. . . 189701 . .

Diode/Capacitor Board,

1

. . . . . . . . . . . . . . . .

. . . .

193183 . .

Conn, Rect Cinch 18 Pin

1

. . . . . . . . . . . . . . . .

. . . .

196602 . .

Plug, Cavity 18,30 Position Cinch Connector

4

. . . . . . . . . . . . . . . .

. . . .

196603 . .

Seal, Switch 6 Position Rotary .250 Shaft

1

. . . . . . . . . . . . . . . .

. . . .

141450 . .

Conn, Rect Metrmate 10skt 1row Plug Cable Lkg

1

. . . . . . . . . . . . . . . .

. . . .

093995 . .

Circuit Breaker, Man Reset 1p 15a 250vac Frict

2

. . . . . . . . . . . . . . . .

. . . .

211292 . .

Conn, Pack 4p 1row Female

1

. . . . . . . . . . . . . . . .

. . . .

211293 . .

Conn, Pack Terminal Position Assurance (Lock)

1

. . . . . . . . . . . . . . . .

. . . .

201109 . .

Harness, Receptacle Auxiliary Power (Includes)

1

. . . . . . . . . . RC1 . . . . 147632 . .

Rcpt, Tw Lk Grd 2p3w 30a 250v *L6−30r

1

. . . . . . . . . GFCI1 . . . 151981 . .

Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi

1

. . . . . . . . . . CB2

. . . . 093996 . .

Supplementary Protector, Man Reset 1p 20a 250vac Frict

1

. . . . . . . . . . . . . . . .

. . . .

201053 . .

Harness, Receptacle Auxiliary Power Export (Includes)

1

. . . . . . . . . GFCI1 . . . 151981 . .

Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi

1

. . . . . . . . . . CB3 . . . . 139266 . .

Supplementary Protector, Man Reset 1p 15a 250vac Frict

1

. . . . . . . . . . CB2

. . . . 093996 . .

Supplementary Protector, Man Reset 1p 20a 250vac

1

OM-4429 Page 84

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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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