Miller Electric 500DX R, OM-129 Connecting To Weld Output Terminals, Selecting Weld Cable Sizes

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4-6. Connecting To Weld Output Terminals


		Open left side door.
		1	Bracket
		Route cables through bracket.
		2 Positive (+) Weld Output
			Terminal
		3	Negative (−) Weld Output
			Terminal
3		For Stick welding Direct Current
		Electrode Positive (DCEP), con-
		nect work cable to − terminal and
		electrode holder cable to +
	2	terminal.
		For Direct Current Electrode Neg-

		ative		(DCEN), reverse cable
		connections.
		If equipped with optional polarity
		switch,		connect electrode holder
		cable to Electrode (−) terminal and
		work cable to Work (+) terminal.
Left Side		For MIG and FCAW welding with

CV option, connect work cable to (−) terminal and wire feeder cable to (+) terminal

Close door.

1

Tools Needed:

3/4 in

ST-158 700

4-7. Selecting Weld Cable Sizes

		Total Cable (Copper) Length In Weld Circuit Not Exceeding

Welding	100 ft (30 m) Or Less		150 ft	200 ft	250 ft	300 ft		350 ft	400 ft
Welding	100 ft (30 m) Or Less		(45 m)	(60 m)	(70 m)	(90 m)		(105 m)	(120 m)
Amperes			(45 m)	(60 m)	(70 m)	(90 m)		(105 m)	(120 m)
Amperes
	10 − 60%	60 − 100%			10 − 100% Duty Cycle
	Duty Cycle	Duty Cycle			10 − 100% Duty Cycle
	Duty Cycle	Duty Cycle

100	4	4	4	3	2	1		1/0	1/0

150	3	3	2	1	1/0	2/0		3/0	3/0

200	3	2	1	1/0	2/0	3/0		4/0	4/0

250	2	1	1/0	2/0	3/0	4/0		2-2/0	2-2/0

300	1	1/0	2/0	3/0	4/0	2-2/0		2-3/0	2-3/0

350	1/0	2/0	3/0	4/0	2-2/0	2-3/0		2-3/0	2-4/0

400	1/0	2/0	3/0	4/0	2-2/0	2-3/0		2-4/0	2-4/0

500	2/0	3/0	4/0	2-2/0	2-3/0	2-4/0		3-3/0	3-3/0

600	3/0	4/0	2-2/0	2-3/0	2-4/0	3-3/0		3-4/0	3-4/0

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your

distributor for the mm2 equivalent weld cable sizes.

S-0007-E

OM-129 647 Page 17

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Contents OM-129 647W ProcessesDescription From Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageElectric Shock can kill ARC Rays can burn eyes and skinEngine Hazards Moving Parts can cause injury Battery Explosion can BlindEngine Exhaust Gases can kill Engine Heat can cause fireEMF Information Principal Safety StandardsRadiation can cause interference ARC Welding can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie LA Chute DE L’APPAREIL peut blesserInformation sur les champs électromagnétiques Principales normes de sécuritéLE Soudage À L’ARC risque de provoquer des interférences Consignes relatives aux stimulateurs cardiaquesSymbols And Definitions − SpecificationsWeld, Power, And Engine Specifications − DefinitionsCurve shows typical fuel use under weld or power loads Dimensions, Weights, And Operating AnglesFuel Consumption 1898 lb 861 kg Engine EndWarranty Minutes Welding Minutes Resting AC Auxiliary PowerDuty Cycle And Overheating 60% Duty Cycle At 500 Amperes Duty Cycle is PercentageCC/DC Standard CV/DC Models With CV Option Volt-Ampere CurvesOptional AC Power Plant Curves Installing Welding Generator − InstallationDo Not Lift Unit From End Airflow Clearance LocationWhen electrolyte is low, add Activating The Dry Charge BatteryCharger Maintain proper levelEngine Prestart Checks Connecting The BatteryConnect Negative − Cable Last Tools Needed 1/2Selecting Weld Cable Sizes Connecting To Weld Output TerminalsInstalling Ether Cylinder Optional Ether Starting Aid After installing cylinder, wait atRemote A/V Control Receptacle RC3 Terminal Strip 2T Connections Optional Remote 14 Receptacle RC3 Information OptionalSocket Stop engineStandard Controls See Section − Operating the Welding GeneratorDescription Of Standard Controls See Section Do not switch under loadIf light goes off, stop engine and check oil level If light goes on, stop engine and check engine beltControls For Models With CV Option See Section This unit has a max OCV control circuit − Operating Auxiliary Equipment Auxiliary power is not affected by weld outputVolt And 240 Volt Duplex Receptacles 120 V 15 a AC Receptacle RC2 240 V 15 a AC Receptacle RC1Gfci Receptacle Option Optional Auxiliary Power ReceptaclesAustralian And South African Receptacle Options British Receptacle OptionSet Engine Control switch to Run when using auxiliary power Connecting Optional Auxiliary Power Plant1011 Load Terminals− Maintenance & Troubleshooting Deutz F3L912 Diesel Engine Maintenance LabelServicing Air Cleaner To clean air filterHose Servicing Fuel And Lubrication Systems Adjusting Engine Speed Servicing Optional Ether Starting Aid1850 Checking And Replacing Alternator Belt To adjust belt tension13 mm Max Tools Needed 11/16 Stop engine To check belt tensionResetting Fan Belt Safety Shutdown Stop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Optional Spark Arrestor MufflerOverload Protection For Models With CV Option Stop engine and let coolWelding TroubleshootingEngine Auxiliary PowerTrouble Remedy OM-129 647 Circuit Diagram For Welding Generator Standard Models − Electrical DiagramsCircuit Diagram For Welding Generator Models With CV Option 184 954-C Wetstacking − RUN-IN ProcedureLoad Bank Run-In Procedure Using Load BankDo not touch hot exhaust Run-In Procedure Using Resistance GridBank/grid From flammables− Auxiliary Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Use ground device as stated in electrical codesApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting Amperage VoltsEmergencies or power outages Generator is to supply standby power duringWelding Generator Auxiliary Power output circuit Customer-supplied equipment is required ifSelecting Extension Cord Use Shortest Cord Possible 101 100 − Parts List66 65 102 Dia Part Description Quantity Mkgs Optional Panel, Front w/Components CC Model Illustrated Panel, Front w/Components -1 Item 6 5 GeneratorGenerator -1 Item 171 Hardware is common Not available unless listedIncludes Control Box CC/CV -1 Item 86 Optional Panel, Mtg Components CC/CV Model Panel, Mtg Components CC Model Page Service Your distributor also givesSupport Miller Electric Mfg. Co To locate distributor nearest you call 1-800-4-A-MillerFor assistance in filing or settling claims