Overload Protection | Miller Electric Big Blue 500 PT manual

9-7. Overload Protection

! Stop engine.

. When a supplementary protector, circuit breaker or fuse opens, it usu- ally indicates a more serious problem exists. Contact Factory Authorized

			Service Agent.
		1	Fuse F1
		2	Fuse F2
		F1 and F2 protect the stator exciter wind-
		ing from overload. If F1 opens, weld and
		generator power is low or stops entirely.
		If F2 opens, weld output is low or stops
		entirely. 4 kVA/kW generator power is still
		available.
2	1	3	Circuit Breaker CB4 (Not Shown)
		3	Circuit Breaker CB4 (Not Shown)
		4	Supplementary Protector CB5
			(CC/CV Models Only)
		5	Supplementary Protector CB6
			(CC/CV Models Only)
		6	Circuit Breaker CB10 (Not Shown)
9		7	Supplementary Protector CB11
8		8	Supplementary Protector CB12
7		9	Supplementary Protector CB13
		9	Supplementary Protector CB13

CB4 protects the welding arc drive (dig) circuit. If CB4 opens, electrode may stick to the workpiece more frequently during low voltage (short arc length) conditions. CB4 automatically resets when the fault is corrected.

CB5 protects the 24 volt ac output to re- mote receptacle RC14, and 24 volt output to field current regulator board PC1 (CC/

4 5CV models only). If CB5 opens, weld out- put and 24 volt output to RC14 stops. On units with optional three-phase genera- tor, generator power output at receptacle RC5 also stops if CB5 opens.

CB6 protects the 115 volt ac output to re- mote receptacle RC14 (CC/CV models only). If CB6 opens, 115 volt output to RC14 stops.

CB10 protects the engine battery circuit. If CB10 opens, the engine will not crank. CB10 automatically resets when the fault is corrected.

CB11 protects the weld control circuit. On CC models, if CB11 opens the max OCV circuit does not work and open circuit voltage is variable at all times (see max OCV note under Weld Controls in Section 6-2). If CB11 opens on CV models, weld output stops (generator power is still available).

CB12 protects the field flashing circuit. If CB12 opens, the generator may not ex- cite at start-up and weld and generator power output may not be available.

CB13 protects the engine control circuit. If CB13 opens, the engine does not crank.

Press button to reset.

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OM-4429 Page 46

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Miller Electric Big Blue 500 PT, Big Blue 600 X manual Overload Protection

Contents

File Engine Drive ProcessesDescription Visit our website at OM-44292216 138H 2007−05 From Miller to You Table of Contents − Maintenance & Troubleshooting Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burns ARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosion Engine Hazards Compressed Air Hazards Fire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injury EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interference UN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation Indique des instructions spécifiques LE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peu DES Organes Mobiles peuvent pro voquer des blessures Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures ’EMPLOI Excessif peut Information EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité En ce qui concerne les implants médicaux Std − Definitions− 50 h Std Manufacturer’s Rating Labels CC Models Symbols And Definitions Some symbols are found only on CE products Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Volt-Ampere Curves For CC Models Volts TIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV Models 100% Duty Cycle At 400 Amperes Fuel ConsumptionDuty Cycle And Overheating 12 kVA/kW Single-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 20 kVA/kW Three-Phase AC Output No Weld Load Location/Airflow Clearance − InstallationInstalling Welding Generator Grounding1 Using Lifting Eye Mounting Welding Generator Installing Exhaust Pipe Stop engine and let cool Activating The Dry Charge Battery If Applicable Connecting The Battery Fuel Coolant Recovery TankEngine Prestart Checks Oil MIG and Fcaw Welding Connecting To Weld Output TerminalsStick and TIG Welding Stop engine 150 ft 200 ft 250 ft Connecting to WeldSelecting Weld Cable Sizes 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket OM-4429 − Operating Welding Generator − CC Models Front Panel Controls For CC Models See Section Engine Gauges And Meters Engine Starting ControlsTo Start Weld Controls Example Combination Remote Amperage Control Stick Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label OM-4429 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See Section Voltage/Amperage Adjust Switch And Remote 14 Receptacle 14 AC/DC Voltmeter Optional Process/Contactor Switch On CC/CV Models Process/Contactor Switch Settings Remote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIG At least once a month, run en − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles If a Supplementary Close panel opening if no connections are made to generator Three-Phase Power ConnectionRear Of Panel Supplementary Protector CB2 Supplementary Protector CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 − Maintenance & Troubleshooting Maintenance Label Routine Maintenance Servicing Air Cleaner To clean air filter Inspecting And Cleaning Optional Spark Arrestor Muffler Checking Generator Brushes To replace primary fuel filter Servicing Fuel And Lubrication SystemsTo change oil and filter Overload Protection Troubleshooting Welding − CC Models Welding − CC/CV Models Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models Only Factory Authorized Service Agent Check engine wiring harness plug connectionsGine Control switch S1 Engine cranks but does not start Check fuel level Start Your Professional Welding Career Now − Electrical Diagrams Circuit Diagram For CC Welding Generator 223 525-B Circuit Diagram For CC/CV Welding Generator 223 524-B Welding Generator − RUN-IN ProcedureWetstacking From flammables Run-In Procedure Using Load BankKeep exhaust and pipe away Just generator A/V control so Run-In Procedure Using Resistance GridSpecifications section in this Manual Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Electrically Bond Generator Use ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = Watts Industrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Single-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 / Volts = Starting Amperage Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible 123 116 CV 112 − Parts List114 −7 115 CV 2831 124 88 −6 6059 58 Dia Part Description Quantity Dia Part Description Quantity Mkgs Figures 13-2 111 123 212 Control Box Assembly − CC Models Control Box Assembly − CC Models -1Item Engine Controller Control Box Assembly − CC/CV Models 134 Panel, Front w/Components − CC Models 3634 208278 Panel, Front w/Components − CC/CV Models Panel, Front w/Components − CC/CV Models -1Item CB1 201 Supplementary PROTECTOR, man reset 2P 20 A, 250VAC Hardware is common 32 31 30 053 BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X Main Rectifier Assembly Wiring Harnesses 215207 Support ServiceYour distributor also gives For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s