Manuals / Miller Electric / Power Tools / Welder

Miller Electric 500D, 600 X manual Control Box Assembly − CC/CV Models

Models: 500D 600 X

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				Figure 15-3. Control Box Assembly − CC/CV Models
Item		Dia.		Part	Description		Quantity
	No.	Mkgs.		No.	Description		Quantity
				Figure 15-3. Control Box Assembly − CC/CV Models (Figure 15-1Item 98)
. . .	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 . . . . CR3			. . .	090 104 . .	RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg		. . . 1
. . . 6 . . . . CR8			. . ♦197 325 . .		RELAY, encl 12vdc spst 70a 4pin flange mtg		. . . 1
. . . 7 . . . . CR1			. . .	214 876 . .	RELAY, encl 6vdc spst 35a/14vdc 5 pin		. . . 1
. . . 8 . . . . CR6			. .	♦090104 . .	RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg		. . . 1
. . . 9 . . . D8/C8			. .	189 701 . .	DIODE/CAPACITOR BOARD		. . . 1
. . . 10 . . .		. CB14	. . .	205 927 . .	CIRCUIT BREAKER, auto reset 12vdc 12 amp		. . . 1
. . . 11 . . .		. CB10	. . .	190 374 . .	CIRCUIT BREAKER, auto reset 12VDC 40A		. . . 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 . . .		. . . . . . .	. . .	201 079 . .	COVER, control box		. . . 1
. . . 16 . . .		. CR4	. . ♦113 247 . .		RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg		. . . 1
. . . 17 . . .		. PC9	. . .	192 224 . .	CIRCUIT CARD ASSY, display	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 1
. . . 18 . . .		. . . . . . .	. . .	134 201 . .	STAND-OFF, support pc card		. . . 3
. . . 19 . . .		. TD1	. . .	214 928 . .	TIMER, delay on make/break open 30 sec 12vdc		. . . 1
. . . 20 . . .		. . C9 .	. . .	. 087 110 . .	CAPACITOR, elctlt 240uf 200VDC		. . . 1
. . . 21 . . .		. . . . . . .	. . .	177 136 . .	CLAMP, capacitor 1.375dia		. . . 1
. . . 22 . . .		D1/C1	. .	189 701 . .	DIODE CAPACITOR BOARD		. . . 1

OM-4428 Page 91

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Miller Electric 500D, 600 X manual Control Box Assembly − CC/CV Models

Contents

File Engine Drive OM-4428215 932KProcesses DescriptionFrom Miller to You Table of Contents Troubleshooting HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationIndique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LE Soudage peut provoquer un in cendie ou une explosionDES Organes Mobiles peuvent pro voquer des blessures ’EXPLOSION DE LA Batterie peuRisque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresEn ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMFStd − Definitions− 50 h Std CC Models Manufacturer’s Rating LabelsSome symbols are found only on CE products Symbols And DefinitionsLifting Eye Weight Rating − SpecificationsWeld, Power, And Engine Specifications Dimensions, Weights, And Operating AnglesVolts Volt-Ampere Curves For CC ModelsVolt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG ModeFuel Consumption Curve shows typical fuel use under weld or power loads100% Duty Cycle At 500 Amperes AC Generator Power CurveDuty Cycle And Overheating 20 kVA/kW Three-Phase AC Output No Weld Load Optional Three-Phase Generator Curves12 kVA/kW Single-Phase AC Output No Weld Load Grounding1 − InstallationInstalling Welding Generator Location/Airflow ClearanceUsing Lifting Eye Mounting Welding Generator Stop engine and let cool Installing Exhaust PipeAfter installing cylinder, wait at Connecting The Battery Activating The Dry Charge Battery If ApplicableFuel Engine Prestart ChecksDeutz F4L2011 Engine Deutz F3L912 EngineMIG and Fcaw Welding Connecting To Weld Output TerminalsCorrect Installation Stick and TIG WeldingOutput terminals Connecting to WeldSelecting Weld Cable Sizes 45 m 60 m 70 m 90 m 105 m 120 mSocket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsFront Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsWeld Controls Engine Starting ControlsTo Start Engine Gauges And MetersExample Combination Remote Amperage Control Stick Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label Work like a Pro Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV Models14 AC/DC Voltmeter Optional Voltage/Amperage Adjust Switch And Remote 14 ReceptacleProcess/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsExample Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models OptionalIf a Supplementary − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles At least once a month, run enAre made Generator Rear Of PanelClose ConnectionsSupplementary Protector CB2 Supplementary Protector CB3 Optional Generator Power Receptacles Standard Models240 V 15 a AC South African Receptacle RC1 Generator power is not affected by weld output Generator Power Receptacles Export ModelsMaintenance Label Deutz F4L2011-Powered Units − Maintenance Deutz F4L2011−POWERED UnitsRoutine Maintenance Deutz F4L2011-Powered Units Checking Generator Brushes To clean air filter Servicing Air Cleaner Deutz F4L2011-Powered UnitsReinstall cleanout plug Tools Needed 3/8 Spark Arrestor Muffler Cleanout PlugCovering cleanout hole Blow out cleanout hole. If nothingModels With Automatic Idle Optional Adjusting Engine Speed Deutz F4L2011-Powered UnitsStandard Models Do not set engine speed higher than specifiedTo replace secondary fuel filter To change oil and filterTo drain water from fuel system To replace primary fuel filterWhen a supplementary protector Overload Protection Deutz F4L2011-Powered UnitsMaintenance Label Deutz F3L912-Powered Units − Maintenance Deutz F3L912−POWERED UnitsRoutine Maintenance Deutz F3L912-Powered Units Checking Generator Brushes Cleanings Ment is not covered by the warrantyClean or replace primary element if dirty See note above before cleaning. ReSpark Arrestor Muffler Cleanout Plug Adjusting Engine Speed Deutz F3L912-Powered Units To change oil and filter Overload Protection Deutz F3L912-Powered Units Welding − CC Models − TroubleshootingTroubleshooting Welding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Only Standard Generator PowerEngine − Electrical Diagrams 215 221-E OM-4428 235 275-A OM-4428 215 806-E OM-4428 235 276-A OM-4428 215 807-D OM-4428 215 808-D Welding Generator − RUN-IN ProcedureWetstacking From flammables Run-In Procedure Using Load BankKeep exhaust and pipe away Manual Run-In Procedure Using Resistance GridSpecifications section in this Just generator A/V control soElectrically Bond Generator − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer FrameAmperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codesFarm/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 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible CC CC Models Only CV CC/CV Models Only − Parts ListDeutz F4L2011 en Dia Part Description Quantity Dia Part Description Quantity Mkgs CC191 Control Box Assembly − CC Models PLG3 Control Box Assembly − CC/CV Models 193 SWITCH, rotary 6 position gold contacts Panel, Front w/Components − CC Models GFCI1 Temp Panel, Front w/Components − CC/CV Models -1Item Panel, Front w/Components − CC/CV ModelsPC6 192 PC4, PC5 189 2827 Hardware is common602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly -1Item Main Rectifier AssemblyPage Support ServiceYour distributor also gives Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact