Miller-electric Big Blue 500 X User Manual

ProcessesDescriptionTIG (GTAW) WeldingStick (SMAW) WeldingMIG (GMAW) WeldingEngine Driven Welding GeneratorOM-4421 215 075N2007−01Visit our website at

OM-4421 Page 4READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and s

OM-4421 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 3/05 Avertissement: Protégez vous et les autres des blessures − lisez

OM-4421 Page 6Le soudage effectué sur des conteneurs fermés tels que desréservoirs, tambours ou des conduites peut provoquer leuréclatement. Des étinc

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, place

OM-4421 Page 8LIRE LES INSTRUCTIONS. Utiliser seulement les pièces de rechange d’origine. Effectuer la maintenance du moteur et du compresseur(si ap

OM-4421 Page 9SECTION 3 − DEFINITIONS3-1. Warning Label Definitions (For Wordless Labels)3/961 Remove unit from shippingcrate. Remove Owner’sManual fr

OM-4421 Page 103-2. Manufacturer’s Rating LabelsCC Models CC/CV ModelsCC Export Models CC/CV Export Models

OM-4421 Page 113-3. Symbols And DefinitionsSome symbols are found only on export products.NOTEStop EngineFast (Run, Weld/Power)Slow (Idle) Start Engin

OM-4421 Page 12SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated WeldingOutputMaximumOpen-CircuitV

OM-4421 Page 134-3. Volt-Ampere Curves For CC Models215 081-AThe volt-ampere curve shows theminimum and maximum voltageand amperage output capabilitie

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

OM-4421 Page 144-4. Volt-Ampere Curves For CC/CV Models215 080-A / 215 083-A / 215 079-AThe volt-ampere curves show theminimum and maximum voltageand

OM-4421 Page 154-5. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.199 032−ADC WELD AMPERES AT 100% DUTY CYCLEUS Gal./Hr.0

OM-4421 Page 164-7. AC Generator Power Curve193 018The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacl

OM-4421 Page 17SECTION 5 − INSTALLATIONinstall3 8/06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 Always securely fasten weld-ing generator on

OM-4421 Page 185-2. Using Lifting EyeRef. 802 3111 Lifting Eye2 Nut3 Carriage BoltRaise lifting eye until it snaps inplace. Lower lifting eye when not

OM-4421 Page 195-3. Mounting Welding GeneratorTools Needed:9/16 in224Welding Unit In PlaceBolting Unit In Place Do not weld on base. Weld-ing on base

OM-4421 Page 205-4. Installing Exhaust Pipe1/2 inTools Needed:Ref. 803 604 / Ref. 215 158 Stop engine and let cool. Point exhaust pipe in desired di

OM-4421 Page 215-5. Activating The Dry Charge Battery (If Applicable) Always wear a face shield,rubber gloves and protectiveclothing when working on

OM-4421 Page 225-7. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break-in

OM-4421 Page 235-8. Connecting To Weld Output Terminals803 602 / 803 778-ATools Needed:23/4 in1MIG and FCAW WeldingFor MIG and FCAW welding Direct Cur

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

OM-4421 Page 245-9. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Less1

OM-4421 Page 255-11. Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsSocket* Socket Information24 VOLTS ACA 24 volts ac. Protected by sup-pleme

OM-4421 Page 26SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS6-1. Front Panel Controls For CC Models (See Section 6-2)12215 070 / 803 60211218131

OM-4421 Page 276-2. Description Of Front Panel Controls For CC Models (See Section 6-1)Engine Starting Controls1 Starting Aid SwitchUse switch to ener

OM-4421 Page 286-3. Remote Amperage Control On CC Models (Optional)1 Remote Amperage AdjustReceptacle RC13Connect optional remote control toRC13 (see

OM-4421 Page 29Notes

OM-4421 Page 30SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS7-1. Front Panel Controls For CC/CV Models (See Section 7-2)215 158 / 803 6022191

OM-4421 Page 317-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)Engine Starting Controls1 Starting Aid SwitchUse switch to e

OM-4421 Page 327-3. Process/Contactor Switch On CC/CV Models1 Process/Contactor Switch Weld output terminals are ener-gized when Process/Contactorswi

OM-4421 Page 337-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see S

TABLE OF CONTENTSSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Front Panel

OM-4421 Page 34SECTION 8 − OPERATING AUXILIARY EQUIPMENT8-1. 120 Volt And 240 Volt Receptacles191 624-A21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 3

OM-4421 Page 358-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)Ref. 197 399 / 802 332-E / 803 655 Place Process/Contactor switch

OM-4421 Page 368-3. Optional Generator Power Receptacles21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 16 A AC EuropeanReceptacle RC13 240 V 15 A AC Au

OM-4421 Page 37SECTION 9 − MAINTENANCE & TROUBLESHOOTING9-1. Maintenance Label

OM-4421 Page 389-2. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Labelfor important start-up, service, and

OM-4421 Page 399-3. Checking Generator BrushesRef 215 158 Stop engine and let cool.1 Generator BrushMark and disconnect leads at brush hold-er cap. R

OM-4421 Page 409-4. Servicing Air Cleaner Stop engine. Do not run engine without aircleaner or with dirty element. En-gine damage caused by using ad

OM-4421 Page 419-5. Inspecting And Cleaning Optional Spark Arrestor Muffler803 656 / Ref. 215 158 Stop engine and let cool.1 Spark Arrestor Muffler2

OM-4421 Page 429-6. Adjusting Engine Speed803 606-CAfter tuning engine, check enginespeed with tachometer or frequencymeter. See table for proper no l

OM-4421 Page 439-7. Servicing Fuel And Lubrication Systems802 490 / Ref. 801 434 Stop engine and let cool. After servicing, start engineand check fo

dec_rot_9/06Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating labe

OM-4421 Page 449-8. Overload Protection803 605219874 Stop engine. When a supplementary protector,circuit breaker or fuse opens, it usu-ally indicate

OM-4421 Page 459-9. TroubleshootingA. Welding − CC ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Check position of

OM-4421 Page 46Trouble RemedyNo remote fine amperage control. Repair or replace remote control device.Have Factory Authorized Service Agent check OCV

OM-4421 Page 47Trouble RemedyNo remote fine amperage or voltagecontrol.Repair or replace remote control device.Have Factory Authorized Service Agent c

OM-4421 Page 48E. EngineTrouble RemedyEngine will not crank. Check battery, and replace if necessary.Check battery connections and tighten if necessar

OM-4421 Page 49Notes

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

OM-4421 Page 51223 522-B

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

OM-4421 Page 53223 523-B

dec_rotsound_6/05Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating

OM-4421 Page 54SECTION 11 − RUN-IN PROCEDURErun_in1 11/0511-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do not

OM-4421 Page 5511-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust

OM-4421 Page 5611-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep e

OM-4421 Page 57SECTION 12 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generato

OM-4421 Page 5812-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4421 Page 5912-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4421 Page 6012-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4421 Page 6112-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-4421 Page 6212-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable cod

OM-4421 Page 6312-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, u

OM-4421 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_3/05 Warning: Protect yourself and others from injury — read and follow these

OM-4421 Page 64SECTION 13 − PARTS LIST Hardware is common andnot available unless listed.400 P ModelsOnly12345678910111314151216171819202122232425262

OM-4421 Page 65803 646-E3334353637383940414243444546474849505152535455565758596162636465666768697071727374757677787980818283858486878889909193 (Fig. 1

OM-4421 Page 66DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main AssemblyQuantity1 189 824 PANEL, gen LH 1. . . . . . . . . . . . . . . . . . . .

OM-4421 Page 67DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity40 ♦202 629 COVER, radiator access ss 1. . . . . . . .

OM-4421 Page 68DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity77 191 626 BUMPER, door engine access 4. . . . . . . .

OM-4421 Page 69DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity120 ♦199 305 TOP, cover front upright ss 1. . . . . .

OM-4421 Page 70 Hardware is common andnot available unless listed.803 647-F212423543614211822201615178117101291913Figure 13-2. Control Box Assembly −

OM-4421 Page 71DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-2. Control Box Assembly − CC Models ContinuedQuantity20 201 079 COVER, control box 1. . .

OM-4421 Page 72803 648-F2312316201819171514511847961222211013Figure 13-3. Control Box Assembly − CC/CV ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure

OM-4421 Page 73DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-3. Control Box Assembly − CC/CV Models (Continued)Quantity20 177 136 CLAMP, capacitor 1.375

OM-4421 Page 2Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flyi

OM-4421 Page 74 Hardware is common andnot available unless listed.803 649123456789111012131415161819202122232425262728293031323433353637383940414217F

OM-4421 Page 75DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 125)Quantity1 215 070 PLATE SCRE

OM-4421 Page 76DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-4. Panel, Front w/Components − CC Models (Continued)Quantity197 798 SENDER, Coolant Temp 30

OM-4421 Page 77DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 125)Quantity1 215 158 PLATE

OM-4421 Page 78DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity38 134 201 STAND-OFF, suppor

OM-4421 Page 79802 552-B Hardware is common andnot available unless listed.568924283031323312725263536431027212934201718111516121314192223Figure 13-6

OM-4421 Page 80DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-6. Generator (Continued)Quantity21 197 486 ADAPTER, Engine 1. . . . . . . . . . . . . . .

OM-4421 Page 81 Hardware is common andnot available unless listed.802 279-A123465789Figure 13-7. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs.It

OM-4421 Page 82 Some wiring harness components (switches, relays, circuit breakers) are also referencedelsewhere in this parts list. Purchase componen

OM-4421 Page 83DescriptionPartNo.Dia.Mkgs.ItemNo.Wiring Harnesses (Continued)Quantity221376 Harness, engine control (includes) 1. . . . . . . . . . .

OM-4421 Page 3STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at o

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2007−01Your distributor also givesyou ...ServiceYou always get the

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