Miller Electric 500 X Manuel du propriétaire

Big Blue 400DBig Blue 500 X(Deutz-Powered)ProcessesDescriptionTIG (GTAW) WeldingStick (SMAW) WeldingMIG (GMAW) WeldingEngine Driven Welding Generato

OM-4425 Page 6WELDING WIRE can injure. Do not press gun trigger until instructed to doso. Do not point gun toward any part of the body,other people,

OM-4425 Page 71-8. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Documents (

OM-4425 Page 8SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONfre_rom_2010−03Pour écarter les risques de blessure pour vous−même et pour aut

OM-4425 Page 9LES PIÈCES CHAUDES peuventprovoquer des brûlures. Ne pas toucher à mains nues les parties chau-des. Prévoir une période de refroidisse

OM-4425 Page 10Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)peuvent affecter les implants médicaux. Les porteurs de stimulateurs cardiaques etautres implants m

OM-4425 Page 11LES ÉTINCELLES À L’ÉCHAPPEMENTpeuvent provoquer un incendie. Empêcher les étincelles d’échappement dumoteur de provoquer un incendie.

OM-4425 Page 12un médecin familiarisé avec ce type de blessure, faute de quoila gangrène pourrait apparaître.Les PIÈCES MOBILES peuvent causerdes bles

OM-4425 Page 13Une PRESSION D’AIR RÉSIDUELLEET DES FLEXIBLES QUI FOUETTENTrisquent de provoquer des blessures. Détendre la pression pneumatique des o

OM-4425 Page 14LES CHARGES ÉLECTROSTATI-QUES peuvent endommager lescircuits imprimés. Établir la connexion avec la barrette de terreavant de manipule

OM-4425 Page 152-8. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Docume

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-4425 Page 16SECTION 3 − DEFINITIONS3-1. Warning Label Definitions (For Wordless Labels)3/961 Remove unit from shippingcrate. Remove Owner’sManual f

OM-4425 Page 173-2. Symbols And Definitions Some symbols are found only on CE products.Stop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineStart

OM-4425 Page 18SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated WeldingOutputMaximumOpen-CircuitV

OM-4425 Page 194-3. Volt-Ampere Curves For CC Models215 081-AThe volt-ampere curve shows theminimum and maximum voltageand amperage output capabilitie

OM-4425 Page 204-4. Volt-Ampere Curves For CC/CV Models215 080-A / 215 083-A / 215 079-AThe volt-ampere curves show theminimum and maximum voltageand

OM-4425 Page 214-5. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.199 032-ADC WELD AMPERES AT 100% DUTY CYCLEUS Gal./Hr.0

OM-4425 Page 224-7. AC Generator Power Curve193 018The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacl

OM-4425 Page 23SECTION 5 − INSTALLATION5-1. Serial Number And Rating Label LocationThe serial number and rating information for this product is locate

OM-4425 Page 245-3. Mounting Welding GeneratorTools Needed:9/16 in.224Welding Unit In PlaceBolting Unit In Place! Do not weld on base. Weld-ing on bas

OM-4425 Page 25! Always ground generatorframe to vehicle frame to pre-vent electric shock and staticelectricity hazards.! Also see AWS Safety &Hea

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1...1-1. Symbol Usage 1...

OM-4425 Page 265-6. Installing Exhaust Pipe1/2 in.Tools Needed:Exhaust1 2008−01 Ref. 803 604 / Ref. 215 664! Stop engine and let cool. Point exhaust

OM-4425 Page 275-7. Activating The Dry Charge Battery (If Applicable)! Always wear a face shield,rubber gloves and protectiveclothing when working on

OM-4425 Page 285-9. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Automatic shutdown system stops e

OM-4425 Page 295-10. Connecting To Weld Output Terminals803 602 / 803 778-BTools Needed:23/4 in.1MIG and FCAW WeldingFor MIG and FCAW welding Direct C

OM-4425 Page 305-11. Selecting Weld Cable Sizes*NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld

OM-4425 Page 315-13. Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsRef. 803 602ORNew! LDR-14 longdistance remote(includes 120 Vreceptacle)Soc

OM-4425 Page 32SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS6-1. Front Panel Controls For CC Models (See Section 6-2)240 162 / 803 6021211218976

OM-4425 Page 336-2. Description Of Front Panel Controls For CC Models (See Section 6-1)Engine Starting Controls1 Starting Aid SwitchUse switch to ener

OM-4425 Page 346-3. Remote Amperage Control On CC Models (Optional)1 Remote Amperage AdjustReceptacle RC13Connect optional remote control toRC13 (see

OM-4425 Page 35Notes16 Gauge (.063 in)22 Gauge (.031 in)24 Gauge (.025 in)20 Gauge (.037 in)18 Gauge (.050 in)14 Gauge (.078 in)1/8 in (.125 in)3/16 i

TABLE OF CONTENTSSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 32...6-1. Front Panel Controls For CC Models (See Sect

OM-4425 Page 36SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS7-1. Front Panel Controls For CC/CV Models (See Section 7-2)240 163 / 802 60211OR

OM-4425 Page 37Engine Starting Controls1 Starting Aid SwitchUse switch to energize starting aid for coldweather starting (see starting instructions fo

OM-4425 Page 387-3. Process/Contactor Switch On CC/CV Models1 Process/Contactor Switch! Weld output terminals are ener-gized when Process/Contactorswi

OM-4425 Page 397-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see S

OM-4425 Page 407-5. Fuel/Hour Gauge Descriptions

OM-4425 Page 41SECTION 8 − OPERATING AUXILIARY EQUIPMENT8-1. Domestic Auxiliary Power Receptacles191 624-A21 120 V 20 A AC GFCI Receptacle GFCI12 240

OM-4425 Page 428-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)Ref. 197 399 / 802 332-E / 803 655 Place Process/Contactor switch

OM-4425 Page 438-3. Export Auxiliary Power Receptacles1 120V 15/20A AC Receptacle GFCI1Receptacles supply 60 Hz single-phasepower at weld/power speed.

OM-4425 Page 44SECTION 9 − MAINTENANCE & TROUBLESHOOTING9-1. Maintenance Label 3020100-10-20-30-4086°F °C77685950413223145-4-13-22-31-405W/30 (Syn

OM-4425 Page 459-2. Routine Maintenance! Stop engine before maintaining. See Engine Manual and Maintenance Labelfor important start-up, service, and

OM-4425 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom_2010−03Protect yourself and others from injury — read, follow, and save these impo

OM-4425 Page 469-3. Operating Optional Oil Pan Heater803 602 / Ref. 803 1451 Optional Oil Heater PlugUse heater to maintain a constantengine oil tempe

OM-4425 Page 479-5. Servicing Air Cleaner! Stop engine.NOTICE − Do not run engine without aircleaner or with dirty element. Enginedamage caused by usi

OM-4425 Page 489-6. Inspecting And Cleaning Optional Spark Arrestor Muffler803 656 / Ref. 236 970! Stop engine and let cool.1 Spark Arrestor Muffler2

OM-4425 Page 499-8. Adjusting Engine Speed803 644 / Ref. 800 159! Stop engine and let cool.Engine speed is factory set andshould not require adjustmen

OM-4425 Page 509-9. Servicing Fuel And Lubrication Systems 803 644 / Ref. 800 159! Stop engine and let cool.! After servicing, start engine andcheck

OM-4425 Page 519-10. Overload Protection803 605219874! Stop engine. When a supplementary protector, cir-cuit breaker or fuse opens, it usuallyindicat

OM-4425 Page 529-11. TroubleshootingA. Welding − CC ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Check position of

OM-4425 Page 53B. Welding − CC/CV ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Place Process/Contactor switch in a

OM-4425 Page 54Trouble RemedyLow CV weld output. Set Ampere Range switch to highest range.Increase Voltage/Amperage Adjust Control setting.Min or max

OM-4425 Page 55E. EngineTrouble RemedyEngine will not crank. Check battery, and replace if necessary.Check battery connections and tighten if necessar

OM-4425 Page 2Welding produces fumes and gases. Breathing thesefumes and gases can be hazardous to your health.FUMES AND GASES can be hazardous. Keep

OM-4425 Page 56SECTION 10 − ELECTRICAL DIAGRAMSFigure 10-1. Circuit Diagram For CC Welding Generator (Domestic Models)

OM-4425 Page 57238 628-A

OM-4425 Page 58Figure 10-2. Circuit Diagram For CC/CV Welding Generator (Domestic Models)

OM-4425 Page 59240 205-C

OM-4425 Page 60Figure 10-3. Circuit Diagram For CC Welding Generator (Export Models)

OM-4425 Page 61240 583-E

OM-4425 Page 62Figure 10-4. Circuit Diagram For CC/CV Welding Generator (Export Models)

OM-4425 Page 63240 206-D

OM-4425 Page 64SECTION 11 − RUN-IN PROCEDURErun_in1 2007−0411-1. Wetstacking1 Welding GeneratorRun diesel engines near rated volt-age and current duri

OM-4425 Page 6511-2. Run-In Procedure Using Load BankS-06831 Load BankTurn all load bank switches Off. Ifneeded, connect load bank to 115volts ac wall

OM-4425 Page 31-3. Engine HazardsBATTERY EXPLOSION can injure. Always wear a face shield, rubber gloves, andprotective clothing when working on a bat

OM-4425 Page 6611-3. Run-In Procedure Using Resistance GridS-06841 Resistance GridUse grid sized for generator ratedoutput.Turn Off grid.2 Welding Gen

OM-4425 Page 67SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding gener

OM-4425 Page 6812-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #8 AWG or larger insulated

OM-4425 Page 6912-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4425 Page 7012-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4425 Page 7112-8. Power Required To Start MotorSingle-Phase Induction Motor Starting RequirementsMotor StartCodeG H J K L M N PKVA/HP 6.3 7.1 8.0

OM-4425 Page 7212-10. Typical Connections To Supply Standby PowerTransfer SwitchEssentialLoadsFusedDisconnectSwitch(If Required) UtilityElectricalServ

OM-4425 Page 7312-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt LoadsIf unit does not have GFCI receptacles, use

OM-4425 Page 74SECTION 13 − PARTS LIST Hardware is common and notavailable unless listed.CC CC Models OnlyCV CC/CV Models Only12345678101112131415161

OM-4425 Page 75803 651-G19202122232425262728 (Fig. 13−7)2930313233343536373839414042434445464748495051525354555657585960616263646566676869707172737475

OM-4425 Page 41-4. Hydraulic HazardsHYDRAULIC EQUIPMENT can injureor kill. Incorrect installation or operation of this unitcould result in equipment

OM-4425 Page 76DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main AssemblyQuantity1 189 824 PANEL, gen LH 1... ... .. ...

OM-4425 Page 77DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity36 *216 959 BELT, blower 1... ... .. ...

OM-4425 Page 78DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity81 218 087 TANK, fuel (consisting of) 1... ...

OM-4425 Page 79803 652-E2111196371422131612515920181784212310Figure 13-2. Control Box Assembly − CC ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-

OM-4425 Page 80DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-2. Control Box Assembly − CC Models (Continued)Quantity22 CB14 ♦205 927 CIRCUIT BREAKER, au

OM-4425 Page 81DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-3. Control Box Assembly − CC/CV Models (Continued)Quantity13 PC7 ♦195 706 MODULE, pull to i

OM-4425 Page 82 Hardware is common andnot available unless listed.803 654-C1110987221312383635373334322021252726242328301819151617142394041163542931F

OM-4425 Page 83DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-4. Panel, Front w/Components − CC Models (Continued)Quantity192 558 HARNESS, range (consist

OM-4425 Page 84 Hardware is common andnot available unless listed.803 655-B11311430275342525150464749443940413837363543342833255545657176810935419242

OM-4425 Page 85DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 107)Quantity1 PLATE SCREENED,

OM-4425 Page 5HOT METAL from air arc cutting andgouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep extin

OM-4425 Page 86DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity46 190 323 BOOT, circuit bre

OM-4425 Page 87805 259-A12345891076Figure 13-6. Auxiliary Power Group, ExportDescriptionPartNo.Dia.Mkgs.ItemNo. QuantityFigure 13-6. Auxiliary Power G

OM-4425 Page 88802 552-B568924283031323312725263536431027212934201718111516121314192223Figure 13-7. Generator

OM-4425 Page 89DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-7. Generator (Figure 13-1 Item 28)Quantity1 132 053 SCREW, .375−16x1.50 hex hd−pln gr5 pld

OM-4425 Page 90 Hardware is common andnot available unless listed.802 279-A123465789Figure 13-8. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs.It

OM-4425 Page 91 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchas

OM-4425 Page 92DescriptionPartNo.Dia.Mkgs.ItemNo.Wiring Harnesses (Continued)Quantity215659 Harness, engine control (includes) 1... .

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2010−01Your distributor also givesyou ...ServiceYou always get the

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2010 Miller Electric Mfg. Co. 2010−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer