Miller Electric 500DX R Description Of Standard Controls See Section, Do not switch under load

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5-2. Description Of Standard Controls (See Section 5-1)

.This unit has a max OCV control circuit

that resets the Amperage/Voltage Con- trol to maximum when the arc breaks. When an arc is struck, weld output con- trol returns to the front panel or remote control setting. The Amperage/voltage Control adjusts amperage only when welding and does not adjust open-circuit voltage.

1 Ampere Range Switch

Use switch to select one of five ampere ranges.

For most welding applications, use lowest amperage range possible to help prevent arc outages.

YDo not switch under load.

2 Amperage/Voltage Control

Control adjusts amperage within range se- lected by Ampere Range switch. Weld output

would be 223 A DC with controls set as shown (50% of 125 to 320 A).

3Remote A/V Control Receptacle And Switch

Connect optional remote control to RC3 (See Section 4-9). Use switch to select front panel or remote amperage control (see example below).

4Manual Stop Control

5Engine Start Button

6Ether Starting Aid Switch (Optional)

Push switch up and release while cranking engine to release ether.

YDo not use Ether if engine is running.

To Start: Press button and use Ether switch (if necessary). Release button when engine starts.

Do not crank engine while engine is turning.

To Stop: Pull control out and hold. Release control when engine stops.

7DC Ammeter (Optional)

8DC Voltmeter (Optional)

9Oil Pressure Warning Light

Light goes off if oil pressure is too low.

YIf light goes off, stop engine and check oil level.

10 Battery Charging Warning Light

Light goes on when battery is not charging.

YIf light goes on, stop engine and check engine belt.

11Engine Hour Meter

12Polarity Switch (Optional)

Example: Combination Remote Amperage Control

In Example:

Range = 125 to 320 A

Percentage Of Range = 50%

Max = 223 A DC (50% of 125 to 320)

			Max (223 A DC)
			Min (100 A DC)
Set Switches	Set Range	Set Percentage	Adjust Optional Remote Control

S-0774 / Ref. ST-180 933-B

OM-129 647 Page 21

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Contents Processes OM-129 647WDescription 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 TerminalsAfter installing cylinder, wait at Installing Ether Cylinder Optional Ether Starting AidRemote 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 LabelTo clean air filter Servicing Air CleanerHose Servicing Fuel And Lubrication Systems Servicing Optional Ether Starting Aid Adjusting Engine Speed1850 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 flammablesSelecting Equipment − Auxiliary Power GuidelinesGrounding 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 Hardware is common Not available unless listed 171Includes Control Box CC/CV -1 Item 86 Optional Panel, Mtg Components CC/CV Model Panel, Mtg Components CC Model Page Your distributor also gives ServiceSupport To locate distributor nearest you call 1-800-4-A-Miller Miller Electric Mfg. CoFor assistance in filing or settling claims