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Manual Miller Electric Big Blue 500 X

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  • Miller Electric Big Blue 500 X - page 1

    Processes Description TIG (GT A W) Welding Stick (SMAW ) Welding MIG (GMAW) Welding Engine Driven Welding Generator OM-4421 215 075N 2007 − 01 Visit our website at www.MillerWelds.com Flux Cored (FCA W ) Welding Air Carbon Arc (CAC-A) Cutting and Gouging File: Engine Drive Big Blue 400P B i g B l u e 5 0 0 X   (Per kins-Power ed) ...

  • Miller Electric Big Blue 500 X - page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your near est distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mill ...

  • Miller Electric Big Blue 500 X - page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 4

    T ABLE OF CONTENTS SECTION 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 3 ...

  • Miller Electric Big Blue 500 X - page 5

    dec_rot_9/06 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W . Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r .l. Phone ...

  • Miller Electric Big Blue 500 X - page 6

    dec_rotsound_6/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Notified Body: Miller Electric Mg. Co. Mr . Danilo Fedolfi, A V T echnology Limited 1635 W . Spencer St. Managing Director A VTECH House Apple ...

  • Miller Electric Big Blue 500 X - page 7

    OM-4421 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05  W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special saf ...

  • Miller Electric Big Blue 500 X - page 8

    OM-4421 Page 2 W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the are ...

  • Miller Electric Big Blue 500 X - page 9

    OM-4421 Page 3 STEAM AND HOT COOLANT can burn.  If possible, check coolant level when engine is cold to avoid scalding.  Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).  If the engine is warm, checking is needed, and there is no overflow ...

  • Miller Electric Big Blue 500 X - page 10

    OM-4421 Page 4 READ INSTRUCTIONS.  Use only genuine MILLER/Hobart replacement parts.  Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio naviga- ...

  • Miller Electric Big Blue 500 X - page 11

    OM-4421 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 3/05  Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par ...

  • Miller Electric Big Blue 500 X - page 12

    OM-4421 Page 6 Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact ac ...

  • Miller Electric Big Blue 500 X - page 13

    OM-4421 Page 7  Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.  Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur .  Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- ver le bouchon. LES ACCUMULA TIONS DE GAZ ris- quent de ...

  • Miller Electric Big Blue 500 X - page 14

    OM-4421 Page 8 LIRE LES INSTRUCTIONS.  Utiliser seulement les pièces de rechange d’origine.  Ef fectuer la maintenance du moteur et du compresseur (s i applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RA YONNEMENT HAUTE FRÉ- QUENCE (H.F .) risque de provoquer des interférences.  Le rayonnement haut ...

  • Miller Electric Big Blue 500 X - page 15

    OM-4421 Page 9 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions (For Wordless Labels) 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muf fler . 2 Read Owner ’s Manual. Read labels on unit. 3 Use Diesel Fuel only , and fill fuel tank. Leave room for expansion. 4 Warning! W atch Ou ...

  • Miller Electric Big Blue 500 X - page 16

    OM-4421 Page 10 3-2. Manufacturer ’ s Rating Labels CC Models CC/CV Models CC Export Models CC/CV Export Models ...

  • Miller Electric Big Blue 500 X - page 17

    OM-4421 Page 1 1 3-3. Symbols And Definitions Some symbols are found only on export products. NOTE Stop Engine Fast (Run, W eld/ Power) Slow (Idle) Start Engine Starting Aid Battery (Engine) Engine Oil Pressure Engine Oil Check Injectors/ Pump Check V alve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/T rained Mechanic W eldi ...

  • Miller Electric Big Blue 500 X - page 18

    OM-4421 Page 12 SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And Engine Specifications W elding Mode W eld Output Range Rated W elding Output Maximum Open- Circuit V oltage Generator Power Rating Engine Fuel Capacity CC/DC 55 − 500 A (CC Models) 15 − 500 A (CC/CV Models) Export Models: 300 A, 32 V olts DC, 100% Duty Cycle 430 A, 37 V olts ...

  • Miller Electric Big Blue 500 X - page 19

    OM-4421 Page 13 4-3. V olt-Ampere Curves For CC Models 215 081-A The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. DC AMPERES DC VOL TS 100 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 Ranges: 230 − Max ...

  • Miller Electric Big Blue 500 X - page 20

    OM-4421 Page 14 4-4. V olt-Ampere Curves For CC/CV Models 215 080-A / 215 083-A / 215 079-A The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. A. Stick Mode B. MIG Mode C. TIG Mode DC VOL TS DC AMPERES DC VOL TS DC AMP ...

  • Miller Electric Big Blue 500 X - page 21

    OM-4421 Page 15 4-5. Fuel Consumption The curve shows typical fuel use under weld or power loads. 199 032 − A DC WELD AMPERES A T 100% DUTY CYCLE US Gal./Hr . 0 50 100 150 200 250 300 350 400 450 500 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 IDLE Continuous Welding 4-6. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- u ...

  • Miller Electric Big Blue 500 X - page 22

    OM-4421 Page 16 4-7. AC Generator Power Curve 193 018 Th e ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 0 50 100 150 200 250 300 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE AC VOL TS 0 25 50 75 100 150 125 0 1 02 03 0 4 05 0 6 0 AC AMPERES IN 120V MODE 4-8. Optional Three-Phase Generator Curves ...

  • Miller Electric Big Blue 500 X - page 23

    OM-4421 Page 17 SECTION 5 − INST ALLA TION install3 8/06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712  Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.  Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity ...

  • Miller Electric Big Blue 500 X - page 24

    OM-4421 Page 18 5-2. Using Lifting Eye Ref. 802 31 1 1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps in place. Lower lifting eye when not needed. T o lock the lifting eye in the upright position, insert a 3/8-16 x 1-1/2 in carriage bolt through slot in bracket a nd secure with nut (bolt and nut not supplied). T ools Needed: 2 1 ...

  • Miller Electric Big Blue 500 X - page 25

    OM-4421 Page 19 5-3. Mounting Welding Generator T ools Needed: 9/16 in 2 2 4 W elding Unit In Place Bolting Unit In Place  Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.  Do not mount unit by sup- porting the base only at the four mounting brackets. Use ...

  • Miller Electric Big Blue 500 X - page 26

    OM-4421 Page 20 5-4. Installing Exhaust Pipe 1/2 in T ools Needed: Ref. 803 604 / Ref. 215 158  Stop engine and let cool.  Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Notes W or k l i ke a P r o! Pros wel d and cut safel y . Read the safety rules at the beginni ng of this manual . ...

  • Miller Electric Big Blue 500 X - page 27

    OM-4421 Page 21 5-5. Activating The Dry Charge Battery (If Applicable)  Always wear a face shield, rubber gloves and protective clothing when working on a battery . Remove battery from unit. 5 V ent Caps 6 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 7 W ell Fill each cell with electrolyte to bottom of well (maximum).  Do not overfill b ...

  • Miller Electric Big Blue 500 X - page 28

    OM-4421 Page 22 5-7. Engine Prestart Checks  Check all engine fluids daily . Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.  This unit has a low oil pressure shut- down switch. However , some condi- tions ...

  • Miller Electric Big Blue 500 X - page 29

    OM-4421 Page 23 5-8. Connecting T o W eld Output T erminals 803 602 / 803 778-A T ools Needed: 2 3/4 in 1 MIG and FC A W Welding For MIG and FCA W welding Direct Current Electrode Positive (DCEP) on CC/CV models, connect wire feeder cable to Positive (+) termi- nal on left and work cable to Negative ( − ) ter- minal on right. Use Process/Contacto ...

  • Miller Electric Big Blue 500 X - page 30

    OM-4421 Page 24 5-9. Selecting W eld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals  Stop engine before connecting to weld out- put terminals.  Do not use worn, ...

  • Miller Electric Big Blue 500 X - page 31

    OM-4421 Page 25 5-1 1. Connecting T o Remote 14 Receptacle RC14 On CC/CV Models Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by sup- plementary protector CB5. 24 VOL TS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG or Stick mode; 0 to +10 volts dc in TIG ...

  • Miller Electric Big Blue 500 X - page 32

    OM-4421 Page 26 SECTION 6 − OPERA TING WELDING GENERA TOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 12 215 070 / 803 602 11 2 1 81 3 1 4 97 6 4 5 3 10 ...

  • Miller Electric Big Blue 500 X - page 33

    OM-4421 Page 27 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1 ) Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). 2 Engine Control Switch Use switch to start and stop engine. T o Start :  Do not use ether . Using ether vo ...

  • Miller Electric Big Blue 500 X - page 34

    OM-4421 Page 28 6-3. Remote Amperage Control On CC Models (Optional) 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-10 ). Example: Combination Remote Amperage Control (Stick) Adjust Optional Remote Control Set Switches Set Range Set Control Ref. 154 862-A / Ref. 181 71 1-A / 803 602 In Example: Range ...

  • Miller Electric Big Blue 500 X - page 35

    OM-4421 Page 29 Notes ...

  • Miller Electric Big Blue 500 X - page 36

    OM-4421 Page 30 SECTION 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 215 158 / 803 602 2 1 91 4 1 5 10 7 6 4 5 11 8 13 OR 12 3 ...

  • Miller Electric Big Blue 500 X - page 37

    OM-4421 Page 31 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1 ) Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). 2 Engine Control Switch Use switch to start engine, select engine speed ( if unit has auto idle option), an ...

  • Miller Electric Big Blue 500 X - page 38

    OM-4421 Page 32 7-3. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch  W eld output terminals are ener- gized when Process/Contactor switch is in an Weld T erminals Always On position and the en- gine is running.  DC voltage is still present at the weld terminals when Process/ Contactor switch is in the Re- mote On/Off Swit ...

  • Miller Electric Big Blue 500 X - page 39

    OM-4421 Page 33 7-4. Remote V oltage/Amperage Control On CC/CV Models (Optional) 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-1 1). 0774 / Ref. 215 158 / Ref. 803 602 Example: Combination Remote Amperage Control (Stick) Adjust Optional Remote Control Set V/A Adjust Switch Set Range Control Not Used In Remote St ...

  • Miller Electric Big Blue 500 X - page 40

    OM-4421 Page 34 SECTION 8 − OPERA TING AUXILIAR Y EQUIPMENT 8-1. 120 V olt And 240 V olt Receptacles 191 624-A 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 30 A AC T wistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, GFCI Reset button pops out and receptacle does not work. C ...

  • Miller Electric Big Blue 500 X - page 41

    OM-4421 Page 35 8-2. Connecting T o Optional Three-Phase Generator (CC/CV Models Only) Ref. 197 399 / 802 332-E / 803 655  Place Process/Contactor switch in W eld T erminals Always On - Stick position when using three- phase generator (see Section 7-3 ). Single-Phase Generator Power 1 120/240 V 50 A Receptacle RC5 RC5 is connected to the optiona ...

  • Miller Electric Big Blue 500 X - page 42

    OM-4421 Page 36 8-3. Optional Generator Power Receptacles 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 16 A AC European Receptacle RC1 3 240 V 15 A AC Australian Receptacle RC1 4 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, the GFCI Reset button pops o ...

  • Miller Electric Big Blue 500 X - page 43

    OM-4421 Page 37 SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Maintenance Label ...

  • Miller Electric Big Blue 500 X - page 44

    OM-4421 Page 38 9-2. Routine Maintenance  Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle engine fluids.  = Check  = Change  = Clean  = Replace * T o be done by Factory Authorized Serv ...

  • Miller Electric Big Blue 500 X - page 45

    OM-4421 Page 39 9-3. Checking Generator Brushes Ref 215 158  Stop engine and let cool. 1 Generator Brush Mark and disconnect leads at brush hold- er cap. Remove brushes. Replace brushes if damaged or if brush material is at o r near minimum length. 1 Damaged Brushes New Length: 1-1/4 in (32 mm) Minimum Length: 5/8 in (16 mm) Replace Notes W or k ...

  • Miller Electric Big Blue 500 X - page 46

    OM-4421 Page 40 9-4. Servicing Air Cleaner  Stop engine.  Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty .  The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each cleaning. The chance of ...

  • Miller Electric Big Blue 500 X - page 47

    OM-4421 Page 41 9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler 803 656 / Ref. 215 158  Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhaust pi ...

  • Miller Electric Big Blue 500 X - page 48

    OM-4421 Page 42 9-6. Adjusting Engine Speed 803 606-C After tuning engine, check engine speed with tachometer or frequency meter . See table for proper no load speed. Start engine and run until warm. On CC models, place Stick/TIG switch in Stick position. On CC/CV models, turn Process/ Contactor switch to Stick − W eld T erminals Always On positi ...

  • Miller Electric Big Blue 500 X - page 49

    OM-4421 Page 43 9-7. Servicing Fuel And Lubrication Systems 802 490 / Ref. 801 434  Stop engine and let cool.  After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary , and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain V alve And Hose 3 Oil Fill Cap 4 Fuel Line 5 Primary Fuel Filter (Fuel/ W at ...

  • Miller Electric Big Blue 500 X - page 50

    OM-4421 Page 44 9-8. Overload Protection 803 605 2 1 9 8 7 4  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 a nd gen ...

  • Miller Electric Big Blue 500 X - page 51

    OM-4421 Page 45 9-9. T roubleshooting A. Welding − CC Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Check position of Ampere Range switch. Check position of optional Polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote control to Remote Amper ...

  • Miller Electric Big Blue 500 X - page 52

    OM-4421 Page 46 T rouble Remedy No remote fine amperage control. Repair or replace remote control device. Have Factory Authorized Service Agent check OCV control circuit. B. Welding − CC/CV Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Weld T erminals Always On position, ...

  • Miller Electric Big Blue 500 X - page 53

    OM-4421 Page 47 T rouble Remedy No remote fine amperage or voltage control. Repair or replace remote control device. Have Factory Authorized Service Agent check PC1 sensing leads (36 and 37), and connections. Constant speed wire feeder does not work. Reset sup plementary protector CB5 or CB6 (see S ection 9-8 ). Check and secure connections to Remo ...

  • Miller Electric Big Blue 500 X - page 54

    OM-4421 Page 48 E. Engine T rouble Remedy Engine will not crank. Check battery , and replace if necessary . Check battery connections and tighten if necessary . Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9- 8). Have Factory Authorized Service Agent check engine wiring harness and components. Che ...

  • Miller Electric Big Blue 500 X - page 55

    OM-4421 Page 49 Notes ...

  • Miller Electric Big Blue 500 X - page 56

    OM-4421 Page 50 SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator ...

  • Miller Electric Big Blue 500 X - page 57

    OM-4421 Page 51 223 522-B ...

  • Miller Electric Big Blue 500 X - page 58

    OM-4421 Page 52 Figure 10-2. Circuit Diagram For CC/CV Welding Generator ...

  • Miller Electric Big Blue 500 X - page 59

    OM-4421 Page 53 223 523-B ...

  • Miller Electric Big Blue 500 X - page 60

    OM-4421 Page 54 SECTION 1 1 − RUN-IN PROCEDURE run_in1 1 1/05 1 1-1. Wetstacking  Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur . 1 Welding Generator Ru n diesel engines near rated volt- ag e and current during run-in period to properly seat piston rings and preve ...

  • Miller Electric Big Blue 500 X - page 61

    OM-4421 Page 55 1 1-2. Run-In Procedure Using Load Bank S-0683  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.  Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur . 1 Load Bank T urn all ...

  • Miller Electric Big Blue 500 X - page 62

    OM-4421 Page 56 1 1-3. Run-In Procedure Using Resistance Grid S-0684  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.  Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur . 1 Resistance Gr ...

  • Miller Electric Big Blue 500 X - page 63

    OM-4421 Page 57 SECTION 12 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. NOTE 12-1. Selecting Equipment gen_pwr 1 1/02 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Prong P ...

  • Miller Electric Big Blue 500 X - page 64

    OM-4421 Page 58 12-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in electric ...

  • Miller Electric Big Blue 500 X - page 65

    OM-4421 Page 59 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 285 ...

  • Miller Electric Big Blue 500 X - page 66

    OM-4421 Page 60 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in ...

  • Miller Electric Big Blue 500 X - page 67

    OM-4421 Page 61 12-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting a ...

  • Miller Electric Big Blue 500 X - page 68

    OM-4421 Page 62 12-10. T ypical Connections T o Supply Standby Power  Have only qualified persons perform these connections according to all applicable codes and safety practic- es.  Properly install and ground this equipment according to its Owner ’s Manual and national, state, and local codes.  Customer -supplied equipment is re- quire ...

  • Miller Electric Big Blue 500 X - page 69

    OM-4421 Page 63 12-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 8 ...

  • Miller Electric Big Blue 500 X - page 70

    OM-4421 Page 64 SECTION 13 − P ARTS LIST  Hardware is common and not available unless listed. 400 P Models Only 1 2 3 4 5 6 7 8 9 10 11 13 14 15 12 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 106 107 108 109 11 0 111 11 2 11 3 1 14 (Fig. 13-2 OR 13-3 11 5 1 16 (CC ONL Y ) 1 17 1 18 (CV) 1 19 (CV) 120 121 122 123 124 125 (Fig. 13-4 OR 13 ...

  • Miller Electric Big Blue 500 X - page 71

    OM-4421 Page 65 803 646-E 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 85 84 86 87 88 89 90 91 93 (Fig. 13 − 6) 95 96 97 98 99 100 101 102 103 104 105 94 ...

  • Miller Electric Big Blue 500 X - page 72

    OM-4421 Page 66 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly Quantity 1 189 824 P ANEL, gen LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 199 294 P ANEL, gen LH ss 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 73

    OM-4421 Page 67 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quantity 40 ♦ 202 629 COVER, radiator access ss 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 191 354 SUPPORT , cover 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 74

    OM-4421 Page 68 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quantity 77 191 626 BUMPER, door engine access 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 199 592 LA TCH, paddle series 20 (black) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 75

    OM-4421 Page 69 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quantity 120 ♦ 199 305 TOP , cover front upright ss 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 212 944 LABEL, cc stick overlap weld ranges 1 . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 76

    OM-4421 Page 70  Hardware is common and not available unless listed. 803 647-F 2 1 24 23 5 4 3 6 14 21 18 22 20 16 15 17 8 11 7 10 12 9 19 13 Figure 13-2. Control Box Assembly − CC Models Description Part No. Dia. Mkgs. Item No. Figure 13-2. Control Box Assembly − CC Models (Figure 13-1 Item 1 14) Quantity 1 F1, F2 *085 874 FUSE, mintr cer s ...

  • Miller Electric Big Blue 500 X - page 77

    OM-4421 Page 71 Description Part No. Dia. Mkgs. Item No. Figure 13-2. Control Box Assembly − CC Models Continued Quantity 20 201 079 COVER, control box 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 C9 087 1 10 CAP ACITOR, elctlt 240uf 200VDC 1 . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 78

    OM-4421 Page 72 803 648-F 23 1 2 3 16 20 18 19 17 15 14 5 11 8 4 7 9 6 12 22 21 10 13 Figure 13-3. Control Box Assembly − CC/CV Models Description Part No. Dia. Mkgs. Item No. Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 1 14) Quantity 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 79

    OM-4421 Page 73 Description Part No. Dia. Mkgs. Item No. Figure 13-3. Control Box Assembly − CC/CV Models (Continued) Quantity 20 177 136 CLAMP , capacitor 1.375dia 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 D1/C1 189 701 DIODE/CAPACITOR BOARD 1 . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 80

    OM-4421 Page 74  Hardware is common and not available unless listed. 803 649 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 33 35 36 37 38 39 40 41 42 17 Figure 13-4. Panel, Front w/Components − CC Models ...

  • Miller Electric Big Blue 500 X - page 81

    OM-4421 Page 75 Description Part No. Dia. Mkgs. Item No. Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 125 ) Quantity 1 215 070 PLA TE SCREENED, ident control rating; when ordering this item, . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 82

    OM-4421 Page 76 Description Part No. Dia. Mkgs. Item No. Figure 13-4. Panel, Front w/Components − CC Models (Continued) Quantity 197 798 SENDER, Coolant T emp 300 Deg F M16 X 1.5 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 217 083 GAUGE, Pressure Oil 0 − 100 Psi Electric 1 . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 83

    OM-4421 Page 77 Description Part No. Dia. Mkgs. Item No. Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 125) Quantity 1 215 158 PLA TE SCREENED, ident control; when ordering this item, . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 84

    OM-4421 Page 78 Description Part No. Dia. Mkgs. Item No. Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued) Quantity 38 134 201 ST AND-OFF , support 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 181 169 SP ACER, output stud 2 . . . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 85

    OM-4421 Page 79 802 552-B  Hardware is common and not available unless listed. 5 6 8 9 24 28 30 31 32 33 1 2 7 25 26 35 36 4 3 10 27 21 29 34 20 17 18 11 15 16 12 13 14 19 22 23 Figure 13-6. Generator Description Part No. Dia. Mkgs. Item No. Figure 13-6. Generator (Figure 13-1 Item 93) Quantity 1 132 053 SCREW, .375 − 16x1.50 hex hd − pln gr ...

  • Miller Electric Big Blue 500 X - page 86

    OM-4421 Page 80 Description Part No. Dia. Mkgs. Item No. Figure 13-6. Generator (Continued) Quantity 21 197 486 ADAPTER, Engine 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 083 883 WASHER, Lock .402idx0.709odx.087t Stl Split10mm 4 . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 87

    OM-4421 Page 81  Hardware is common and not available unless listed. 802 279-A 1 2 3 4 6 5 7 8 9 Figure 13-7. Main Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 13-7. Main Rectifier Assembly (Figure 13-1 Item 1 17) Quantity SR3 215 910 RECTIFIER, environment (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 88

    OM-4421 Page 82 Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness. Note Description Part No. Dia. Mkgs. Item No. Wiring Harnesses Quantity 215054 Harness, control box, CC weld control (includes) 1 . . . . . ...

  • Miller Electric Big Blue 500 X - page 89

    OM-4421 Page 83 Description Part No. Dia. Mkgs. Item No. Wiring Harnesses (Continued) Quantity 221376 Harness, engine control (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10/C10, D1 1/C1 1 189701 Diode/Capacitor Board, 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 500 X - page 90

    ...

  • Miller Electric Big Blue 500 X - page 91

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe ...

  • Miller Electric Big Blue 500 X - page 92

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 9 20-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters − ...

Manufacturer Miller Electric Category Welding System

Documents that we receive from a manufacturer of a Miller Electric Big Blue 500 X can be divided into several groups. They are, among others:
- Miller Electric technical drawings
- Big Blue 500 X manuals
- Miller Electric product data sheets
- information booklets
- or energy labels Miller Electric Big Blue 500 X
All of them are important, but the most important information from the point of view of use of the device are in the user manual Miller Electric Big Blue 500 X.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Miller Electric Big Blue 500 X, service manual, brief instructions and user manuals Miller Electric Big Blue 500 X. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Miller Electric Big Blue 500 X.

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A complete manual for the device Miller Electric Big Blue 500 X, how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Miller Electric Big Blue 500 X by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Miller Electric Big Blue 500 X.

A complete Miller Electric manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Miller Electric Big Blue 500 X - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Miller Electric Big Blue 500 X, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Miller Electric Big Blue 500 X, that we can find in the current document
3. Tips how to use the basic functions of the device Miller Electric Big Blue 500 X - which should help us in our first steps of using Miller Electric Big Blue 500 X
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Miller Electric Big Blue 500 X
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Miller Electric Big Blue 500 X in a specific country, if it was not possible to solve the problem on our own.

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