Miller Electric 500DX R, OM-129 manual This unit has a max OCV control circuit

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5-4. Description Of Controls For Models With CV Option (See Section 5-3)

.This unit has a max OCV control circuit

that resets Amperage/Voltage Control R1 to maximum when the arc breaks. When an arc is struck, weld output con- trol returns to the R1 front panel or com- bination front panel/remote control setting. The Amperage/Voltage control adjusts amperage only when constant current (CC) welding and does not ad- just open-circuit voltage. The max OCV control circuit does not function when constant voltage (CV) welding.

1 Ampere Range Switch

YDo not switch under load.

Use switch to select one of five ampere ranges. Use the lower four ranges for CC welding. Use the highest range for CV/DC welding.

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

2 Amperage/Voltage Control

With CC/CV switch in CC position, use con- trol to adjust amperage within range selected by Ampere Ranges switch. With switch in CV position, use control to adjust voltage.

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

3Manual Stop Control

4Engine Start Button

5Ether 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.

6DC Ammeter (Optional)

7DC Voltmeter (Optional)

8Oil Pressure Warning Light

Light goes off if oil pressure is too low.

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

9 Battery Charging Warning Light

Light goes on when battery is not charging.

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

10Engine Hour Meter

11Polarity Switch (Optional)

12Constant Current/Constant Voltage (CC/CV) Switch

Use switch to select type of weld output. Use

CCfor Stick (SMAW) welding. Use CV for wire feed processes (MIG, FCAW). If using CV, place Ampere Range switch in maxi- mum position.

13 Output/Contactor Switch

YWeld output terminals are energized when Output/Contactor switch is On and engine is running

Use switch to control remote contactor con- nected to Remote 14 receptacle RC3 or ter- minal strip 2T.

For weld output, place switch in the On posi- tion. Open-circuit voltage is present at the weld output terminals whenever engine is running.

For remote output control, place switch in Remote position. Open-circuit voltage is present at the weld output terminals when remote contactor switch is closed.

14 Amperage/Voltage Control Switch

Use switch to select front panel or remote amperage and voltage adjustment.

For front panel control, place switch in Panel position. For remote control, place switch in Remote position and connect remote control to Remote 14 receptacle RC3 or terminal strip 2T.

Example: Combination Remote Amperage Control

In Example:

Mode = CC

 

 

Range = 125 to 320 A DC

 

Percentage Of Range = 50%

 

Min = 125 A DC

 

Max = 223 A DC

 

(50% of 125 to 320)

Max

(223 A DC)

Min

(125 A DC)

Set Switches

Set Range

Set Percentage

Adjust Remote Control

S-185 440 / Ref. ST-185 762-B / S-0774

OM-129 647 Page 23

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Contents OM-129 647W ProcessesDescription From Miller to You Table of Contents Page ARC Rays can burn eyes and skin Symbol UsageArc Welding Hazards Electric Shock can killEngine Hazards Engine Heat can cause fire Battery Explosion can BlindMoving Parts can cause injury Engine Exhaust Gases can killARC Welding can cause interference Principal Safety StandardsEMF Information Radiation can cause interferenceLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures gravesLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chaleur DU Moteur peut pro- voquer un incendieConsignes relatives aux stimulateurs cardiaques Principales normes de sécuritéInformation sur les champs électromagnétiques LE Soudage À L’ARC risque de provoquer des interférences− Definitions − SpecificationsSymbols And Definitions Weld, Power, And Engine Specifications1898 lb 861 kg Engine End Dimensions, Weights, And Operating AnglesCurve shows typical fuel use under weld or power loads Fuel Consumption60% Duty Cycle At 500 Amperes Duty Cycle is Percentage AC Auxiliary PowerWarranty Minutes Welding Minutes Resting Duty Cycle And OverheatingCC/DC Standard CV/DC Models With CV Option Volt-Ampere CurvesOptional AC Power Plant Curves Location − InstallationInstalling Welding Generator Do Not Lift Unit From End Airflow ClearanceMaintain proper level Activating The Dry Charge BatteryWhen electrolyte is low, add ChargerTools Needed 1/2 Connecting The BatteryEngine Prestart Checks Connect Negative − Cable LastSelecting Weld Cable Sizes Connecting To Weld Output TerminalsInstalling Ether Cylinder Optional Ether Starting Aid After installing cylinder, wait atRemote A/V Control Receptacle RC3 Stop engine Remote 14 Receptacle RC3 Information OptionalTerminal Strip 2T Connections Optional SocketStandard Controls See Section − Operating the Welding GeneratorIf light goes on, stop engine and check engine belt Do not switch under loadDescription Of Standard Controls See Section If light goes off, stop engine and check oil levelControls For Models With CV Option See Section This unit has a max OCV control circuit 120 V 15 a AC Receptacle RC2 240 V 15 a AC Receptacle RC1 Auxiliary power is not affected by weld output− Operating Auxiliary Equipment Volt And 240 Volt Duplex ReceptaclesBritish Receptacle Option Optional Auxiliary Power ReceptaclesGfci Receptacle Option Australian And South African Receptacle OptionsLoad Terminals Connecting Optional Auxiliary Power PlantSet Engine Control switch to Run when using auxiliary power 1011− 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 Stop engine To check belt tension To adjust belt tensionChecking And Replacing Alternator Belt 13 mm Max Tools Needed 11/16Resetting Fan Belt Safety Shutdown Stop engine and let cool Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug Overload Protection For Models With CV OptionWelding 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 BankFrom flammables Run-In Procedure Using Resistance GridDo not touch hot exhaust Bank/grid− Auxiliary Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Use ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 = Starting Amperage Volts Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsCustomer-supplied equipment is required if Generator is to supply standby power duringEmergencies or power outages Welding Generator Auxiliary Power output circuitSelecting 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
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