Miller Electric Big Blue 600 X Uživatelský manuál

Big Blue 500DBig Blue 600 XOM-4428 215 932FSeptember 2004Visit our website atwww.MillerWelds.comProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and

OM-4428 Page 6LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon util

OM-4428 Page 96DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity36 PC4, PC5 189 744 CIRCUIT

OM-4428 Page 97802 404-C Hardware is common andnot available unless listed.56892227282930317242510263433321243231718111314121519202116Figure 15-6. Ge

OM-4428 Page 98DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-6. Generator (Continued)Quantity21 049 026 SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln 4. . . .

OM-4428 Page 99 Hardware is common andnot available unless listed.802 279-A123465789Figure 15-7. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs.It

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/04Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-4428 Page 7L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protectio

OM-4428 Page 8LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur.

OM-4428 Page 9SECTION 3 − DEFINITIONS3-1. Warning Label Definitions (For Wordless Labels)3/96Warning! Watch Out! There arepossible hazards as shown by

OM-4428 Page 103/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Do not smoke and keepmatches and flames away frombattery.3

OM-4428 Page 113/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Hot muffler and exhaust pipescan cause severe burns. Donot

OM-4428 Page 121 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Fire hazard from leakingengine fuel. Fire can result fromweldi

OM-4428 Page 133/961 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinstructions to install muffler.2 Read Owner’s Manual. Read

OM-4428 Page 143-3. Symbols And DefinitionsSome symbols are found only on CE products.NOTEStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineSta

OM-4428 Page 15SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeldOutputRangeRated WeldingOutputMaximumOpen-CircuitVo

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

OM-4428 Page 164-3. Volt-Ampere Curves For CC Models203 412The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities

OM-4428 Page 174-4. Volt-Ampere Curves For CC/CV Models217 811 / 203 415 / 217 810The volt-ampere curves show theminimum and maximum voltageand ampera

OM-4428 Page 184-5. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.193 0930 50 100 150 200 250 300 350 400 450 500DC WELD A

OM-4428 Page 19Continuous Welding4-6. Duty Cycle And OverheatingDuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overhe

OM-4428 Page 204-8. Optional Three-Phase Generator Curves197 472 / 197 473The ac power curves show the gen-erator power available in amperesat the sin

OM-4428 Page 21SECTION 5 − INSTALLATIONinstall3 6/04 − Ref. 800 652 / Ref. 800 477-A / 803 274 Always securely fasten weld-ing generator onto transpo

OM-4428 Page 225-2. Using Lifting EyeRef. 802 3111 Lifting Eye2 Nut3 Carriage BoltRaise lifting eye until it snaps inplace. Lower lifting eye when not

OM-4428 Page 235-3. Mounting Welding GeneratorTools Needed:9/16 in2234Welding Unit In PlaceBolting Unit In Place Do not weld on base. Weld-ing on bas

OM-4428 Page 245-4. Installing Exhaust Pipe1/2 inTools Needed:Ref. 803 604 / Ref. 215 664 Stop engine and let cool. Point exhaust pipe in desired di

OM-4428 Page 255-5. Activating The Dry Charge Battery (If Applicable)Remove battery from unit.1 Eye Protection − SafetyGlasses Or Face Shield2 Rubber

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

OM-4428 Page 265-6. Connecting The Battery1/2 in−+ Connect Negative (−) Cable Last.Tools Needed:Ref. 215 664 / 803 605 / S-0756-C Reinstall cover af

OM-4428 Page 275-8. 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-4428 Page 285-9. Connecting To Weld Output Terminals803 602Tools Needed:23/4 in1 Stop engine.1 Positive (+) Weld Output Terminal2 Negative (−) Wel

OM-4428 Page 295-11. Connecting To Remote Amperage Adjust Receptacle RC13 On CC ModelsRef. 154 862-A / 048 720-K / 803 6021 Remote Amperage AdjustRece

OM-4428 Page 305-12. Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsSocket* Socket Information24 VOLTS ACA 24 volts ac. Protected by circuitbr

OM-4428 Page 31NotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

OM-4428 Page 32SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS6-1. Front Panel Controls For CC Models (See Section 6-2)12215 663 / 803 6021121813

OM-4428 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-4428 Page 346-3. Remote Amperage Control On CC Models (Optional)1 Remote Amperage AdjustReceptacle RC13Connect optional remote control toRC13 (see

OM-4428 Page 35NotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

TABLE OF CONTENTSSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Front Panel

OM-4428 Page 36SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS7-1. Front Panel Controls For CC/CV Models (See Section 7-2)215 664 / 802 6022191

OM-4428 Page 377-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)Engine Starting Controls1 Starting Aid SwitchUse switch to e

OM-4428 Page 387-3. Process/Contactor Switch On CC/CV Models1 Process/Contactor Switch Weld output terminals are ener-gized when Process/Contactorswi

OM-4428 Page 397-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see S

OM-4428 Page 40SECTION 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-4428 Page 418-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)Ref. 197 399 / 802 332-B / 803 655 Place Process/Contactor switch

OM-4428 Page 428-3. Optional Generator Power Receptacles (Standard Models)21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 16 A AC EuropeanReceptacle RC1

OM-4428 Page 438-4. Generator Power Receptacles (Export Models) Generator power is not affected by weldoutput.1 130 V 32 A AC Receptacle RC12 220 Vo

OM-4428 Page 44SECTION 9 − MAINTENANCE (DEUTZ F4L2011−POWERED UNITS)The oil/filter maintenance intervals are different for the Deutz F4L2011 and F3L91

OM-4428 Page 45Every 1000 hChange Oil Filter.See Section 9-6.Service more oftenin dirty conditions.Change Oil. SeeSection 9-6.Service WeldingGenerator

OM-4428 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_8/03 Warning: Protect yourself and others from injury — read and follow these

OM-4428 Page 469-2. Maintenance Label (Deutz F4L2011-Powered Units)

OM-4428 Page 479-3. Servicing Air Cleaner (Deutz F4L2011-Powered Units)aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B Stop engine. Do

OM-4428 Page 489-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units)803 656 / Ref. 215 664 Stop engine and let cool.1 Spark

OM-4428 Page 499-5. Adjusting Engine Speed (Deutz F4L2011-Powered Units)803 657 Stop engine and let cool.Engine speed is factory set andshould not re

OM-4428 Page 509-6. Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units)803 657 Stop engine and let cool. After servicing, start eng

OM-4428 Page 519-7. Overload Protection (Deutz F4L2011-Powered Units)Ref. 803 657219874 Stop engine. When a circuit breaker or fuseopens, it usually

OM-4428 Page 52SECTION 10 − MAINTENANCE (DEUTZ F3L912−POWERED UNITS) Follow the storage procedure in the engine owner’s manual if the unit will not be

OM-4428 Page 53Every 500 hChange Oil Filter.See Section 10-7.Service more oftenin dirty conditions.Change Oil. SeeSection 10-7.Repair OrReplaceCracked

OM-4428 Page 5410-2. Maintenance Label (Deutz F3L912-Powered Units)

OM-4428 Page 5510-3. Servicing Air Cleaner (Deutz F3L912-Powered Units)aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B Stop engine. Do

OM-4428 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-4428 Page 5610-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units)803 656 / Ref. 215 664 Stop engine and let cool.1 Spark

OM-4428 Page 5710-5. Adjusting Engine Speed (Deutz F3L912-Powered Units)803 658 / 134 730-C Stop engine.Engine speeds have been factoryset and should

OM-4428 Page 5810-7. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units)803 658 Stop engine and let cool. After servicing, start eng

OM-4428 Page 5910-8. Overload Protection (Deutz F3L912-Powered Units)Ref. 803 658219874 Stop engine. When a circuit breaker or fuse opens,it usually

OM-4428 Page 60SECTION 11 − TROUBLESHOOTING11-1. TroubleshootingA. Welding − CC ModelsTrouble RemedyNo weld output; generator power outputokay at ac r

OM-4428 Page 61B. Welding − CC/CV ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Place Process/Contactor switch in a

OM-4428 Page 62Trouble RemedyLow CV weld output. Set Ampere Range switch to highest range.Increase Voltage/Amperage Adjust Control setting.Min or max

OM-4428 Page 63E. EngineTrouble RemedyEngine will not crank. Check battery, and replace if necessary.Check battery connections and tighten if necessar

OM-4428 Page 64SECTION 12 − ELECTRICAL DIAGRAMSFigure 12-1. Circuit Diagram For CC Welding Generator (Deutz F4L2011-Powered Units)

OM-4428 Page 65215 221-D

OM-4428 Page 3STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at o

OM-4428 Page 66Figure 12-2. Circuit Diagram For CC/CV Welding Generator (Deutz F4L2011-Powered Units)

OM-4428 Page 67215 806-D

OM-4428 Page 68Figure 12-3. Circuit Diagram For CC Welding Generator (Deutz F3L912-Powered Units)

OM-4428 Page 69215 807-C

OM-4428 Page 70Figure 12-4. Circuit Diagram For CC/CV Welding Generator (Deutz F3L912-Powered Units)

OM-4428 Page 71215 808-C

OM-4428 Page 72SECTION 13 − RUN-IN PROCEDURErun_in1 8/0113-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do note

OM-4428 Page 7313-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust

OM-4428 Page 7413-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep e

OM-4428 Page 75SECTION 14 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generato

OM-4428 Page 4READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and s

OM-4428 Page 7614-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4428 Page 7714-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4428 Page 7814-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4428 Page 7914-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-4428 Page 8014-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable cod

OM-4428 Page 8114-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, u

OM-4428 Page 82SECTION 15 − PARTS LIST Hardware is common and notavailable unless listed. A Deutz F4L2011 engine-pow-ered unit is shown below. Seein

OM-4428 Page 83803 659 / 803 665Deutz F3L912 Engine A Deutz F4L2011 en-gine-powered unit isshown below. See in-sert for parts specific toa Deutz F3L9

OM-4428 Page 84DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-1. Main AssemblyQuantity1 189 824 PANEL, gen LH 1. . . . . . . . . . . . . . . . . . . .

OM-4428 Page 85DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-1. Main Assembly (Continued)Quantity♦175 937 BRACKET, support solenoid 1. . . . . . . . .

OM-4428 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez

OM-4428 Page 86DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-1. Main Assembly (Continued)Quantity88 189 908 VALVE, drain fuel 180deg 1. . . . . . . . .

OM-4428 Page 87803 660211119637142213161251592018178421232410Figure 15-2. Control Box Assembly − CC ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-

OM-4428 Page 88DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-2. Control Box Assembly − CC Models (Continued)Quantity215 013 HARNESS, unit weld control (

OM-4428 Page 89803 6611212318149687101351617201541921112223Figure 15-3. Control Box Assembly − CC/CV ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15

OM-4428 Page 90DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-3. Control Box Assembly − CC/CV Models (Continued)Quantity196 602 PLUG, cavity 18,30 positi

OM-4428 Page 91 Hardware is common andnot available unless listed.803 662111098722131239373638343532202125272624232830181915161714240414216354293133F

OM-4428 Page 92DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-4. Panel, Front w/Components − CC Models (Continued)Quantity192 558 HARNESS, range (consist

OM-4428 Page 93DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-4. Panel, Front w/Components − CC Models (Continued)Quantity35 HM 210 424 METER, hour 12-24

OM-4428 Page 94 Hardware is common andnot available unless listed.803 6631154535251464749256555758176810935412134548504244394041383736354334311430272

OM-4428 Page 95DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity6 S6 193 234 SWITCH, rotary