Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Big Blue 600 X Selecting Weld Cable Sizes, 150 ft 200 ft 250 ft, Output terminals

Models: Big Blue 600 X Big Blue 500 PT

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5-9.

Selecting Weld Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

100 ft (30 m) or Less

150 ft

200 ft

250 ft

300 ft

350 ft

400 ft

(45 m)

(60 m)

(70 m)

(90 m)

(105 m)

(120 m)

Weld Output

Terminals

!

Stop engine

before

Welding

10 − 60%

60 − 100%

connecting to

weld

Duty

Duty

10 − 100% Duty Cycle

output terminals.

Amperes

Cycle

Cycle

!Do not use worn, dam- aged, undersized, or poorly spliced cables.

	100		4 (20)	4 (20)	4 (20)	3 (30)	2 (35)	1 (50)	1/0 (60)	1/0 (60)

	150		3 (30)	3 (30)	2 (35)	1 (50)	1/0 (60)	2/0 (70)	3/0 (95)	3/0 (95)

	200		3 (30)	2 (35)	1 (50)	1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	4/0 (120)

	250		2 (35)	1 (50)	1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	2 ea. 2/0	2 ea. 2/0
	250		2 (35)	1 (50)	1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	(2x70)	(2x70)
									(2x70)	(2x70)

	300		1 (50)	1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	2 ea. 2/0	2 ea. 3/0	2 ea. 3/0
	300		1 (50)	1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	(2x70)	(2x95)	(2x95)
								(2x70)	(2x95)	(2x95)

	350		1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	2 ea. 2/0	2 ea. 3/0	2 ea. 3/0	2 ea. 4/0
	350		1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	(2x70)	(2x95)	(2x95)	(2x120)
							(2x70)	(2x95)	(2x95)	(2x120)

	400		1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	2 ea. 2/0	2 ea. 3/0	2 ea. 4/0	2 ea. 4/0
	400		1/0 (60)	2/0 (70)	3/0 (95)	4/0 (120)	(2x70)	(2x95)	(2x120)	(2x120)
							(2x70)	(2x95)	(2x120)	(2x120)

	500		2/0 (70)	3/0 (95)	4/0 (120)	2 ea. 2/0	2 ea. 3/0	2 ea. 4/0	3 ea. 3/0	3 ea. 3/0
	500		2/0 (70)	3/0 (95)	4/0 (120)	(2x70)	(2x95)	(2x120)	(3x95)	(3x95)
						(2x70)	(2x95)	(2x120)	(3x95)	(3x95)

	*Chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.
	**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.
	( ) = mm2 for metric use									S-0007-F

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models

1 Remote Amperage Adjust Receptacle RC13

Connect optional remote control to RC13 (see Section 6-3).

1

Ref. 154 862-A / 048 720-K / 803 602

OM-4429 Page 27

Image 31

Miller Electric Big Blue 600 X Selecting Weld Cable Sizes, 150 ft 200 ft 250 ft, Connecting to Weld, Output terminals

Contents

Visit our website at OM-44292216 138H 2007−05 ProcessesDescription File Engine Drive From Miller to You Table of Contents − Maintenance & Troubleshooting HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can kill Welding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skin Compressed Air Hazards Engine Hazards Falling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazard Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF Information Indique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuer LE 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 explosion DES Organes Mobiles peuvent pro voquer des blessures ’EXPLOSION DE LA Batterie peu ’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessures En ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMF − 50 h Std − DefinitionsStd CC Models Manufacturer’s Rating Labels Some symbols are found only on CE products Symbols And Definitions Weld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles Volts Volt-Ampere Curves For CC Models Volt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG Mode Duty Cycle And Overheating Fuel Consumption100% Duty Cycle At 400 Amperes 20 kVA/kW Three-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 12 kVA/kW Single-Phase AC Output No Weld Load Grounding1 − InstallationInstalling Welding Generator Location/Airflow Clearance Using Lifting Eye Mounting Welding Generator Stop engine and let cool Installing Exhaust Pipe Connecting The Battery Activating The Dry Charge Battery If Applicable Oil Coolant Recovery TankEngine Prestart Checks Fuel Stop engine Connecting To Weld Output TerminalsStick and TIG Welding MIG and Fcaw Welding 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Connecting to WeldSelecting Weld Cable Sizes 150 ft 200 ft 250 ft Socket Connecting To Remote 14 Receptacle RC14 On CC/CV Models OM-4429 Front Panel Controls For CC Models See Section − Operating Welding Generator − CC Models Weld Controls Engine Starting ControlsTo Start Engine Gauges And Meters Weld Control/Arc Condition Information Label Remote Amperage Control On CC Models OptionalExample Combination Remote Amperage Control Stick OM-4429 Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV Models 14 AC/DC Voltmeter Optional Voltage/Amperage Adjust Switch And Remote 14 Receptacle Process/Contactor Switch Settings Process/Contactor Switch On CC/CV Models Example Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models Optional If a Supplementary − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles At least once a month, run en Rear 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 Label − Maintenance & Troubleshooting Routine Maintenance To clean air filter Servicing Air Cleaner Checking Generator Brushes Inspecting And Cleaning Optional Spark Arrestor Muffler To change oil and filter Servicing Fuel And Lubrication SystemsTo replace primary fuel filter Overload Protection Welding − CC Models Troubleshooting Welding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Only Standard Generator PowerEngine Engine cranks but does not start Check fuel level Check engine wiring harness plug connectionsGine Control switch S1 Factory Authorized Service Agent Start Your Professional Welding Career Now Circuit Diagram For CC Welding Generator − Electrical Diagrams 223 525-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 Manual Run-In Procedure Using Resistance GridSpecifications section in this Just generator A/V control so Electrically Bond Generator − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer Frame Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codes Farm/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 Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment KVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements Typical 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 111 Figures 13-2 123 212 Control Box Assembly − CC Models Engine Controller Control Box Assembly − CC Models -1Item Control Box Assembly − CC/CV Models 134 3634 Panel, Front w/Components − CC Models 208278 Panel, Front w/Components − CC/CV Models -1Item Panel, Front w/Components − CC/CV Models CB1 201 Supplementary PROTECTOR, man reset 2P 20 A, 250VAC 32 31 30 Hardware is common 053 BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X Main Rectifier Assembly Wiring Harnesses 215207 Your distributor also gives ServiceSupport 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