Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Big Blue 500 PT, Big Blue 600 X manual Control Box Assembly − CC/CV Models

Models: Big Blue 600 X Big Blue 500 PT

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				Figure 13-3. Control Box Assembly − CC/CV Models
Item		Dia.		Part	Description	Quantity
	No.	Mkgs.		No.	Description	Quantity
				Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1Item 111)

. . .	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 . . . . CR8			. . .	197 325 . .	RELAY, encl 12vdc spst 70a 4pin flange mtg	. . . 1
. . . 6 . . . . CR1			. . .	090 104 . .	RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg	. . . 1
. . .	7 . Engine Controller			219 848 . .	MODULE, control governor	. . . 1
. . .	. . . . . . .	. LE3	. . .	204 702 . .	CORE, torodial .187 id x .375 od x .125 thk	. . . 1
. . . 8 . . . . CR6			. .	♦090104 . .	RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg	. . . 1
. . . 9 . . D10/C10 .				189 701 . .	DIODE/CAPACITOR BOARD	. . . 1
. . . 10 . . . .		CB10	. . .	190 374 . .	CIRCUIT BREAKER, Auto Reset 12vdc 40 Amp	. . . 1
. . . 11 . . . .		. . . . . .	. . .	201 079 . .	COVER, control box	. . . 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 . . . .		CR4	. . ♦113 247 . .		RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg	. . . 1
. . . 16 . . . .		PC9	. . .	192 224 . .	CIRCUIT CARD ASSY, display	. . . 1

OM-4429 Page 74

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Miller Electric Big Blue 500 PT, Big Blue 600 X manual Control Box Assembly − CC/CV Models

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 LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion 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 − Definitions − 50 h StdStd Manufacturer’s Rating Labels CC Models Symbols And Definitions Some symbols are found only on CE products − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models Volts TIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV Models Fuel Consumption Duty Cycle And Overheating100% Duty Cycle At 400 Amperes 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 Remote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Combination Remote Amperage Control Stick 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 Three-Phase Power Connection Rear Of PanelClose panel opening if no connections are made to generator Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Supplementary Protector CB2 Supplementary Protector CB3 − Maintenance & Troubleshooting Maintenance Label Routine Maintenance Servicing Air Cleaner To clean air filter Inspecting And Cleaning Optional Spark Arrestor Muffler Checking Generator Brushes Servicing Fuel And Lubrication Systems To change oil and filterTo replace primary fuel filter Overload Protection Troubleshooting Welding − CC Models Welding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine 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 − RUN-IN Procedure WetstackingWelding Generator Run-In Procedure Using Load Bank Keep exhaust and pipe awayFrom flammables 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 − Parts List 114 −7 115 CV123 116 CV 112 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 Service Your distributor also givesSupport 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