User manual | Big Blue® 500 Pro

Big Blue 500 Pro
Issued April 2013 • Index No. ED/11.0
®
Quick
Specs
Heavy Industrial Applications
Processes
Heavy Construction
Structural Steel
Mining Maintenance
Maintenance and Repair Rigs
Process Piping
Stick (SMAW)
MIG (GMAW)
Flux-Cored (FCAW)
DC TIG (GTAW)
Air Carbon Arc (CAC-A)
3/8-inch (10 mm) carbons
Air Plasma Cutting and Gouging with
optional Spectrum models
Diesel Engine-Driven
Welder/AC Generator
Output Range
DC Stick/TIG 20 – 500 A
DC MIG/FCAW 14 – 40 V
Generator Output Rated at 104˚ F (40˚ C)
3-Phase 21,000 watts peak, 15,000 watts continuous
1-Phase 15,000 watts peak, 12,000 watts continuous
Accu-Rated™– Not Inflated
Generator Power
The Power of Blue .
®
Electronic engine display
simultaneously displays fuel level,
engine hours, coolant temperature,
oil pressure, battery volts, and engine
RPM. Also tracks oil change intervals
and displays engine diagnostics for
quick and easy servicing.
Deutz D2.9 L4 Tier 4 Final
compliant diesel.
The cleanest, greenest
diesel power available. Utilizes Diesel
Oxidation Catalyst (DOC) technology
to keep the air clean with NO exhaust
aftertreatment maintenance.
Low OCV Stick is a simple design that
reduces the open-circuit voltage to 15
volts when the welding power source is
not in use. This feature is now built into
the Big Blue 500 Pro for increased
operator safety without compromising
arc starts.
Auto Remote Sense™ (ARS) detects
if a remote control is plugged into the
14-pin receptacle and eliminates
confusion of a remote/panel switch.
Thermal overload protection
prevents machine damage if the
duty cycle is exceeded or airflow
is blocked.
Infinite arc control allows the arc
characteristics to be changed for
specific applications in Stick, MIG
and FCAW.
Remote oil drain prevents spills and
makes servicing easy.
Standard features include digital
preset weld meters, automatic idle
and 120 V block heater.
The Vault — ultimate control
board reliability. See page 4.
Welder/generator is warranted by Miller for 3 years, parts and labor.
Engine is warranted separately by engine manufacturer.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
Website
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
MillerWelds.com
Specifications
Weld
Output
Range
Weld Mode/
Process
(Subject to change without notice.)
Weld Output
Rated at 104˚ F (40˚ C)
CC/DC
(Stick/TIG)
20 – 500 A
400 A at 36 V, 100% Duty Cycle*
450 A at 38 V, 60% Duty Cycle*
500 A at 38 V, 40% Duty Cycle
CV/DC
(MIG/FCAW)
14 – 40 V
400 A at 36 V, 100% Duty Cycle*
450 A at 38 V, 60% Duty Cycle*
500 A at 38 V, 40% Duty Cycle
Max. OpenCircuit
Voltage
Generator Power Output
Rated at 104˚ F (40˚ C)***
85 VDC
15 VDC**
3-phase: 21,000 watts peak,
15,000 watts continuous
Sound Levels
at 23 ft. (7 m)
Idle:
71.7 dB (95.9 Lwa),
77.9 dB at one meter
1-Phase: 15,000 watts peak,
from front panel
12,000 watts continuous
Weld (500 A Load):
78.3 dB (103.1 Lwa),
83.7 dB at one meter
from front panel
Dimensions
Weight
H: 47 in.
(1194 mm)
H: 55 in.
(1397 mm)
(to top of
exhaust)
W: 28.5 in.
(724 mm)
D: 69.5 in.
(1765 mm)
Net: 1800 lb.
(816.5 kg)
Ship: 1851 lb.
(839.6 kg)
Additional
165 lb. (75 kg)
when fuel
tank is full
*Meets NEMA and IEC ratings. **Sense voltage for Stick and Lift-Arc™ TIG. ***Will operate either 60 Hz or 50/60 Hz power tools, lights, etc.
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
Engine Specifications
(Engines warranted separately by the engine manufacturer.)
Engine Brand
Features
HP
Type
Engine Speeds
Capacities
Automatic Engine
Shutdown
Deutz
D2.9 L4
EPA Tier 4 Final compliant
diesel engine
34.8
4-cylinder, liquid-cooled
industrial diesel
Idle: 1350 RPM
Weld: 1890 RPM
Fuel: 25 gal. (95 L)
Oil: 8.5 qt. (8 L)
Coolant: 16 qt. (15.2 L)
Low Oil Pressure,
High Coolant Temperature,
Low Fuel Level
Performance Data
FUEL CONSUMPTION CURVE
SIMULTANEOUS WELDING AND POWER
2.25
Weld
Amperes
Total Aux. Power Available (Watts)
1-Phase*
3-Phase
No Weld Output
16,000
15,000
1.25
200 A at 28 V
16,000
15,000
1.00
300 A at 32 V
13,000
13,750
0.75
400 A at 36 V
6,500
7,500
450 A at 38 V
4,500
6,750
500 A at 38 V
0
0
2.00
US Gal./Hr.
1.75
1.50
0.50
IDLE
0.25
0.00
0
50
100
150
200
250
300
350
400
DC WELD AMPERES AT 100% DUTY CYCLE
2
450
500
*Single-phase listings include 4000 watts from the exciter stator.
Function Guide
1. Self-Calibrating Digital Weld Meters with
Fault Code Indication display preset or
actual weld parameters.
2. Adjustable Arc Control adjusts DIG when
process control is in Stick mode and adjusts
inductance when process control is in
FCAW or MIG mode. The amount of DIG
determines how much amperage (heat)
varies with Stick arc length. Inductance
determines the “wetness” of the weld puddle.
3. Amperage/Voltage Adjust Control
™
4. Hot Start provides positive Stick electrode
starts making it easy to start all types
of electrodes and it also works great for
bead tie-ins.
5. Great FCAW/MIG Performance and
Arc Starts make the Big Blue® 500 Pro’s arc
best in its class. Easy to run all wires from
.023-inch solid wires to large-diameter
1/8-inch flux-cored wires.
6. Lift-Arc™ TIG with Auto-Stop™
13. Electronic Engine Display can display fuel
level, engine hours, coolant temperature,
oil pressure, battery volts, and engine RPM
simultaneously or one at a time. Also tracks
oil change intervals and displays engine
diagnostics for service technicians.
13
1
2
3
4
5
14
15
6
7
16
8
9
10
11
12
17
14. Engine Control Switch is used to start
engine and then select between Auto Idle
and High Speed Lock. Glow plug operation
is controlled by the engine control module
and automatically occurs as needed by
ambient conditions.
15. Standard 14-Pin Receptacle for simple
connection of remote controls and wire
feeders. It features Auto Remote Sense™
which automatically switches from panel to
remote amperage/voltage (A/V) control with
remote connected. Eliminates confusion of
the Panel/Remote A/V switch.
®
16. Weatherproof Lexan Nameplate is super
durable and resists cracking and fading.
Color coding is for ease of operation.
18
Receptacles and Circuit Breakers
7. 120 and 240 Volt Circuit Breakers
8. 50 A, Three-Phase Circuit Breaker
9. 50 A, 120/240 VAC Receptacle (For matching plug, order #119 172.)
10. 50 A, 240 VAC, Three-Phase Receptacle (For matching plug, order #254 140.)
11. 20 A, 120 VAC Receptacles with Ground Fault
12. 20 A, 240 VAC Receptacles
17. Optional Polarity Reversing Switch
changes DC polarity without the use of tools.
18. Weld Output Terminals
ARC START with Lift-Arc
™
Touch or scratch
Lift at any angle
Shielding
gas
Arc
Workpiece
ARC END with Auto-Stop
™
Shielding
gas
• Reduces or
eliminates
sticking
• Reduces or
eliminates
electrode/work
contamination
• Low opencircuit voltage
For Auto-Stop, lift up to terminate arc
While welding
Shielding
gas
Arc
Workpiece
Lift up
until arc
ends
Arc ends
without
flare
Move back
down to
maintain gas
coverage
• Eliminates need for a
remote control
• Maintains shielding
gas coverage
• Eliminates tungsten
and workpiece
contamination
• Eliminates unwanted
arc strikes outside
the weld area
3
What Makes Miller Industrial Engine Drives So
®
Superior Circuit Board Design
Our critical circuit boards are engineered to carry low power and low
heat to reduce thermal stress and minimize expansion and contraction.
In contrast, our competitor’s boards carry high power and high heat,
making them more vulnerable to failure.
?
Rigorous Testing for Tough,
Real-World Conditions
To prove our machines go to the
limit, Miller industrial engine drives
are put to the test in very extreme
environmental conditions.
• Airborne dust and sand. Critical
components are exposed to
abusive airborne particles in a
special testing chamber for weeks,
helping make sure they’ll operate
while facing extreme levels of dirt,
dust or sand on the jobsite.
“The Vault” Makes Upgrading to Miller CC/CV Units
Worry-Free
Concerns with circuit board reliability have resulted in some operators
steering clear of CC/CV welder/generators — even though they offer
a superior arc and multiple welding processes. Miller circuit board
reliability isn’t a concern since all Big Blue multiprocess industrial
engine drives feature the Vault.
Created out of two aluminum halves sealed with silicone, as well as
watertight harness connections, the Vault provides a clean circuit
board environment, protecting the electronics — and controlling
output — in heavy industrial applications. No other competitor
protects their electronics with a sealed vault, leaving critical circuit
boards exposed to harsh elements that can disrupt the machine’s
electronics, and therefore, its operation.
• Humidity and corrosion. Inside
our Houston testing room, critical
components are subjected to
extended moisture and corrosive
salt exposure to ensure they’ll run
even when exposed to humid
climates, corrosive coastal
environments, and driving rain.
• Temperature extremes. Miller industrial engine drives are tested
to ensure performance in scorching heat. All Miller engine-driven
machines are weld rated at 104 degrees Fahrenheit, but actual tests are
conducted up to 122 degrees Fahrenheit to assure peak performance.
• Jobsite/over-the-road abuse. Miller industrial engine drives are
shaken for hours on transportation bed simulators, subjected to severe
vibration, and test-dropped and jerked to ensure they’ll withstand the
stresses that can shut down competitive machines.
• Continuous operation. Miller industrial engine drives run day and
night, in all weather conditions, to assure they’ll perform without
interruption in the field.
Why Industrial Engine Drive
Customers Choose Miller
The ultimate test of Miller reliability
is how it performs in the field.
These pictures provide a glimpse
of how Miller industrial engine
drives perform for customers.
Read the full stories, and many
others demonstrating our superior
reliability, at MillerWelds.com.
4
Genuine Miller Accessories
®
Polarity Reversing Switch Kit
#301 112 Field
Changes DC polarity without the use of tools.
Female
Receptacle
Adapter Cord, Full KVA #300 517 Field
NEMA 14-50P to NEMA 6-50R. Adapts engine
drive 120/240 V plug to common Millermatic®
and Spectrum® 240 V plug.
Full KVA Plug Kit Field
#119 172 1-Phase,
120/240 VAC, 50 A plug
(NEMA 14-50P)
#254 140 3-Phase,
240 VAC, 50 A plug
(NEMA 15-50P)
Deutz Engine Filter Kit #262 459 Field
Includes all filters required for proper engine
maintenance. Oil filter, primary and secondary
fuel filter, and primary air filter.
Protective Cover
#301 113 Field
Blue water-resistant
canvas cover resists
stains and mildew, and
protects the finish of
your welder.
Note: Protective cover cannot be used with cable holder.
Stick (SMAW) Welding
Weld Leads
2/0 Stick Cable Set, 50 ft. (15 m) #173 851
Consists of 50-foot (15 m) 2/0 electrode cable
with holder, and 50-foot (15 m) work cable with
clamp. 350 A, 100% duty cycle.
2/0 Stick Cable Set, 100/50 ft. (30.5/15 m)
#043 952
Consists of 100-foot (30.5 m) 2/0 electrode
cable with holder, and 50-foot (15 m) work
cable with clamp. 300 A, 100% duty cycle.
XR™ Wire Feeders and Guns
Push-pull system designed to handle difficult-tofeed soft alloy wires such as aluminum. See Lit.
Index No. M/1.7, M/1.71, and M/1.73.
MIG (GMAW)/Flux-Cored (FCAW) Guns
Miller produces a complete line of dependable
MIG guns. See Lit. Index Nos. AY/15.0, AY/16.0
and AY/17.0.
TIG (GTAW) Welding
Dynasty® 200 Series
For premium portable
AC/DC TIG arc quality.
See Lit. Index No. AD/4.8.
SuitCase® X-TREME™ 8VS Wire Feeder
#951 182
SuitCase® X-TREME™ 12VS Wire Feeder
#951 543
Lightweight, voltage-sensing wire feeders
include secondary contactor, gas valve and drive
roll kit. See Lit. Index No. M/6.41 and M/6.42.
Vandalism Lockout Kit
#399 802 Field
Lockable hinged steel panels
cover and protect name plate
gauges and ignition switch
(padlock included).
Cable Holder
#043 946 Field
Saddle-bag-style cable
holder. Convenient wraparound storage of coiled
cable for transportation.
Stores 100 feet of 2/0 cable
on each side.
WC-24 Control #137 549
Use with Spoolmatic 30A.
MIG (GMAW) or Flux-Cored (FCAW)
Spark Arrestor Kit
#195 012 Field
Prevents particles
from leaving the
muffler that could
potentially start a fire. Mandatory when
operating on California grasslands, brush, or
forest-covered land, and in all National Forests.
For other areas, check your state and local laws.
Meets U.S. Forest Service standard 5100-1B.
FA-1D Lockable Flame Arrestor
Fuel Cap #043 947 Field
Fuel cap can be padlocked to
prevent vandalism. A built-in flame
arrestor prevents flames or sparks
from entering the fuel tank.
Spoolmatic® 30A Spool Gun #130 831
Air-cooled, 200-amp, 1-pound spool gun for
aluminum MIG. See Lit. Index No. M/1.73.
Plasma Cutting
Spectrum 375 X-TREME and 625 X-TREME shown.
SuitCase® 8RC Wire Feeder #951 186
SuitCase® 12RC Wire Feeder #951 188
Lightweight and flexible enough to run a variety
of wires up to .062-inch diameter. Includes
remote voltage control and drive roll kit. See Lit.
Index No. M/6.5.
Spectrum® 375 X-TREME™ #907 529
See Lit. Index No. PC/9.2.
Spectrum® 625 X-TREME™ #907 531
See Lit. Index No. PC/9.6.
Spectrum® 875 #907 390-01-1
See Lit. Index No. PC/9.8.
The Spectrum 375 X-TREME and 625
X-TREME come complete with protective
X-CASE™ (not shown).
Note: For best results do not weld when cable is coiled!
Protective cover cannot be used with cable holder.
5
Genuine Miller Accessories
®
Remote Controls
Wireless Remote Hand
Control #300 430
For remote current,
voltage and contactor
control. Receiver plugs
directly into the 14-pin
receptacle of Miller
machine. 300-foot
(91.4 m) operating range. Requires Wireless
Antenna Kit #300 749.
(Continued)
RHC-14 Hand Control
#242 211 020
Miniature hand control for
remote current, voltage
and contactor control.
Dimensions: 4 x 4 x 3.25 inches
(102 x 102 x 82 mm). Includes 20-foot (6 m)
cord and 14-pin plug.
RFCS-14 HD Foot
Control #194 744
Heavy-duty foot
control for remote
current, voltage and
contactor control.
Includes 20-foot (6 m)
cord and 14-pin plug.
Wireless Antenna Kit #300 749
Required for Pro Series engine drives. Optional
on other compatible Miller products where
improved reception is desired.
Trailers and Hitches
Extension Cables for 14-Pin
Remote Controls or 24 VAC Wire Feeders
#242 208 025 25 ft. (7.6 m)
#242 208 050 50 ft. (15.2 m)
#242 208 080 80 ft. (24.4 m)
Mounting Specifications
(Note: Trailers are shipped unassembled.)
H
A
4 holes
Front Panel
B
C
D
4 West Four-Wheel Steerable
Off-Road Trailer #042 801
A heavy-duty 2570-pound (1166 kg) capacity
trailer designed for use in mines, quarries, and
other rough terrain. Has narrow 22-foot (6.7 m)
turning radius. Includes 3-inch (76 mm) lunette
eye, universal hitch and safety chains.
HWY-224 Trailer
#043 805 For highway use.
OFR-224 Trailer
#043 802 For off-road use.
A 2650-pound (1202 kg) capacity trailer. Welded
steel tubing frame, heavy-duty axle with roller
bearing hubs and leaf-spring suspension.
Includes jack stand and 2-inch (50 mm) ball
hitch. HWY-224 also includes fenders and lights.
Cable Tree #043 826
Provides an area to conveniently wrap weld
cables and extension cords.
Dual Hitch #300 831
2-inch (50 mm) ball hitch
and 3-inch (76 mm)
lunette eye in one
reversible assembly.
Trailer Specifications
A.
B.
C.
D.
E.
F.
G.
H.
*With mounting brackets in center position. Dimensions
vary with location of mounting brackets.
(Subject to change without notice.)
Gross Vehicle
Weight Rating
Net
Payload
Height
of Bed
Road
Clearance
Track (Center
to center of
tires)
Standard Tires
(Standard rating
or P-size rating)
4 West
2000 lb./axle
(907 kg/axle)
3000 lb.
(1361 kg)
2570 lb.
(1166 kg)
21.25 in.
(540 mm)
8 in.
(203 mm)
55.25 in.
(1403 mm)
HWY-224
OFR-224
3500 lb.
(1588 kg)
2960 lb.
(1343 kg)
2650 lb.
(1202 kg)
18.5 in.
(470 mm)
7.5 in.
(191 mm)
52 in.
(1321 mm)
*Does not include tongue. **Width at outside of fenders.
6
29.812 in. (757 mm)
27.5 in. (699 mm)
1 in. (25 mm)
11.625 in. (295 mm)*
46.375 in. (1178 mm)*
58 in. (1473 mm)*
69.5 in. (1765 mm)
.562 in. (14 mm) diameter
Height: 45.5 in. (1156 mm) to top of cover
55 in. (1397 mm) to top of exhaust
(exhaust measurement subject to change)
Width: 28.5 in. (724 mm)
(mounting brackets turned in)
30.75 in. (781 mm)
(mounting brackets turned out)
Gross Axle
Weight Rating
Model
E
F
G
Dimensions
Net
Weight
B78-13
Length: 91 in. (2311 mm)*
Width: 61.25 in. (1556 mm)
430 lb.
(195 kg)
B78-13
Length: 105 in. (2667 mm)
Width: HWY– 59.5 in. (1511 mm)**
OFR– 58.438 in. (1484 mm)
320 lb.
(145 kg)
Typical Installations
Electrode Hot
Remote Control
Stick (SMAW) Basic Equipment
RHC-14
Wireless Remote Hand Control
Wireless Antenna Kit
#242 211 020
#300 430
#300 749
14-Pin
RHC-14
Stick Electrode
Wireless
OR
Remote
Hand Control
Work
Flux-Cored/MIG (FCAW/GMAW)
Basic Equipment
SuitCase® X-TREME™ 8VS
SuitCase® X-TREME™ 12VS
Voltage-Sensing Feeder
SuitCase
X-TREME
8VS/12VS
#951 182
#951 543
Flux-Cored or MIG Gun
Work
TIG Torch
with Valve
Lift-Arc TIG (GTAW) Basic Equipment
™
Lift-Arc TIG
Work
Remote On/Off Required
Remote Control
Stick (SMAW) Basic Equipment
RHC-14
Wireless Remote Hand Control
Wireless Antenna Kit
#242 211 020
#300 430
#300 749
14-Pin
RHC-14
Stick Electrode
Wireless
OR
Remote
Hand Control
Work
Flux-Cored/MIG (FCAW/GMAW)
Basic Equipment
SuitCase® 8RC
SuitCase® 12RC
14-Pin
Flux-Cored or MIG Gun
SuitCase
8RC/12RC
#951 186
#951 188
Work
Spoolmatic 30A Gun
Aluminum MIG (GMAW) Basic Equipment
®
Spoolmatic 30A
WC-24
#130 831
#137 549
14-Pin
WC-24
Work
Plasma Basic Equipment
Spectrum® 375 X-TREME™ #907 529
Spectrum® 625 X-TREME™ #907 531
Spectrum® 875
#907 390-01-1
Cutting Torch
Spectrum
Work
7
Ordering Information
Equipment and Options
Stock No.
Description
#907 561
#907 561-001
Base model with 240-volt 3-phase power
Deluxe model with Polarity Reversing Switch and Vandalism Lockout Kit
Polarity Reversing Switch Kit
#301 112
Field. Changes DC polarity without the use of tools
Adapter Cord, Full KVA
#300 517
Field
Full KVA Plug Kit
#119 172
#254 140
Field. 1-phase, 120/240 VAC, 50 A
Field. 3-phase, 240 VAC, 50 A
Deutz Engine Filter Kit
#262 459
Field. Includes air, oil and fuel filters
Spark Arrestor Kit
#195 012
Field
FA-1D Lockable Flame Arrestor Fuel Cap
#043 947
Field. Padlock NOT included
Vandalism Lockout Kit
#399 802
Lockable front control panel and engine compartment
Cable Holder
#043 946
Field. Stores up to 200 feet of 2/0 cable
Protective Cover
#301 113
Field. Canvas cover — will not fit over machine with Cable Holder attached
Stick Welding Leads
#173 851
#043 952
2/0, 350 A, 100% duty cycle, 50-ft. (15 m) stinger, 50-ft. (15 m) work clamp
2/0, 300 A, 100% duty cycle, 100-ft. (30.5 m) stinger, 50-ft. (15 m) work clamp
SuitCase® X-TREME™ 8VS
#951 182
See Lit. Index No. M/6.41
SuitCase® X-TREME™ 12VS
#951 543
See Lit. Index No. M/6.42
SuitCase® 8RC
#951 186
See Lit. Index No. M/6.5
SuitCase® 12RC
#951 188
See Lit. Index No. M/6.5
®
Big Blue 500 Pro
Qty.
Field Accessories
Flux-Cored/MIG Welding
Spoolmatic 30A Spool Gun
#130 831
Requires WC-24 Control. See Lit. Index No. M/1.73
WC-24 Control
#137 549
See Lit. Index No. M/1.5
®
XR™ Wire Feeder Control and Guns
See Lit. Index No. M/1.7, M/1.71, and M/1.73
Flux-Cored (FCAW) and MIG (GMAW) Guns
See Lit. Index Nos. AY/15.0, AY/16.0 and AY/17.0
TIG Welding
Dynasty® 200 Series
See Lit. Index No. AD/4.8
Coolant System
See Lit. Index No. AY/7.2
Plasma Cutting
Spectrum® 375 X-TREME™
#907 529
Includes X-CASE™. See Lit. Index No. PC/9.2
™
#907 531
Includes X-CASE™. See Lit. Index No. PC/9.6
#907 390-01-1
See Lit. Index No. PC/9.8
Spectrum 625 X-TREME
®
Spectrum® 875
Remote Controls
Wireless Remote Hand Control
#300 430
Wireless Antenna Kit
#300 749
RHC-14 Hand Control
#242 211 020
RFCS-14 HD Foot Control
#194 744
Extension Cables
#242 208 025
#242 208 050
#242 208 080
25 ft. (7.6 m)
50 ft. (15.2 m)
80 ft. (24.4 m)
4 West Four-Wheel Steerable Trailer
#042 801
Trailer with lunette eye, universal hitch and safety chains. For off-road use
HWY-224 Trailer
#043 805
Trailer with lights, fenders and 2-inch (50 mm) ball hitch. For highway use
OFR-224 Trailer
#043 802
Trailer with 2-inch (50 mm) ball hitch. For off-road use
Cable Tree
#043 826
Trailer-mounted cable holder for HWY-224 or OFR-224
Dual Hitch
#300 831
Combination 2-inch (50 mm) ball hitch and 3-inch (76 mm) lunette eye in one
reversible assembly. For HWY-224 or OFR-224
Required for wireless remotes when using Pro Series engine drives
Trailers and Hitches
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Price

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