edx5-3.miller 500 eco. pdf
DESCRIPTION
EDX5-3.Miller 500 Eco. PDFManual Book & Data logTRANSCRIPT
ProcessesStick (SMAW)Flux-Cored (FCAW) DC TIG (GTAW) Air Carbon Arc (CAC-A) thru 8-mm (5/16 in.) carbons
Heavy IndustrialApplicationsPipe Welding Structural General FabricationMaintenance and RepairRental Fleets
Big Blue® 500X Eco Pro Diesel Engine-DrivenWelder/AC Generator
Issued June 2012 • Index No. EDX/5.3
Simple operation. Operator-friendlycontrol panel is simplified with color-coded terminals to get you connectedquickly and correctly.
Compact package. The Big Blue 500XEco Pro is up to 44 percent smaller and41 percent lighter than other models—taking less room and reducingtransportation costs.
An Eco-nomical and Eco-friendlyalternative. Designed to be up to 25 percent more fuel-efficient duringtypical welding operations than othermodels. Output of the engine matchesthe power required, saving operatingcost and the environment. The fuelsavings really add up when runningday-after-day, while producing fewercarbon emissions. Meets tough EPATier 4i compliance standards.
High efficiency. Three-phase, rotating-field welding generator requires lessfuel and horsepower to operate.
The Power of Blue®.
Welder/generator is warranted by Miller for 3 years, parts and labor.Engine is warranted separately by engine manufacturer.
Output Range DC CAC-A 20 – 500 A DC Stick 20 – 450 A DC TIG 20 – 450 A FCAW 14 – 40 V
Generator Output Rated at 40˚ C (104˚ F) 5500 Watts Peak, 4000 Watts Continuous
Quiet operation. In weld mode with 71.5 decibels at 7 meters, it’s up to 10 decibels quieter than competitive models, improving jobsitecommunication and safety.
Thermal overload protection preventsmachine damage if the duty cycle isexceeded or airflow is blocked.
QuickSpecs
Meter maintenance displays• Fuel gauge• Hour meter function• Oil change interval• High coolant temperature and low
oil pressure shutdowns • Low fuel shutdown — engine shuts
down before system runs out offuel, making restarts easy.
Accu-Rated™–Not Inflated Generator Power
The Big Blue 500X Eco Pro is arugged, compact, fuel-efficientdiesel welder/generator that’sEco-friendly and Eco-nomical.
See page 3 for more machine features/benefits.
Superior arc performance • Factory-preset DIG settings (Stick)• Hot Start™ (Stick)• Lift-Arc™ TIG with Auto-Stop™
and Crater-out
EPA Tier 4iCompliantEPA Tier 4i
CompliantEPA Tier 4i
CompliantEPA Tier 4i
Compliant
Mitsubishi S4L2 four-cylinder diesel.Heavy-duty industrial engine isdesigned to operate over 10,000 hoursbefore the first basic overhaul. Backedby worldwide support and service.
The Vault — ultimate controlboard reliability. See page 4.
Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA
WebsiteMillerWelds.com
Equipment Sales US and CanadaPhone: 866-931-9730FAX: 800-637-2315International Phone: 920-735-4554International FAX: 920-735-4125
500
600
200
300
400
DUTY CYCLE CURVE
% DUTY CYCLE
CAC-A
STICK/TIG/FCAW
WEL
D AM
PERE
S
0 10 20 30 40 50 60 70 80 90 100
FCAW MODE V/A CURVE STICK/GOUGE MODE V/A CURVE
AUXILIARY POWER CURVE
1.752.002.252.502.753.00
6.627.578.529.46
10.4111.36
0.000.250.500.751.001.251.501.752.002.252.502.753.00
0 50 100 150 200 250 300 350 400 450 500
US G
al./H
r.
DC WELD AMPERES AT 100% DUTY CYCLE
FUEL CONSUMPTION CURVE
IDLE
ECONOMY MODE
POWER MODE
WELD AMPERESTOTAL POWER
AVAILABLE IN WATTS
300/500
0/300
N/A
4000
—
20
—
18
SIMULTANEOUS WELDING AND POWER TABLE
.951.902.843.794.735.696.627.578.529.46
10.4111.36
Lite
rs/H
r.
TIG MODE V/A CURVE
0
20
40
60
80
100
0 100 200 300 400 500 600
DC V
OLTS
DC AMPERES
MIN – ECONOMY MODE
MAX – POWER MODE
350A – ECONOMY MODE
MAX – POWER MODE
(GOUGE)
110 V RECEPTACLEAMPERES
220 V RECEPTACLEAMPERES
100
150
200
250
300
50
75
100
150
125
0
50
100
150
200
250
300
0 5 10 15 20 25 30 35 40 45 50
AC V
OLTS
AC AMPERES IN 240V MODE
0
25
50
75
100
150
125
0 20 40 60 80 100AC AMPERES IN 120V MODE
10 30 50 70 90
0
20
40
60
80
100
0 100 200 300 400 500 600 700 800 900
DC V
OLTS
DC AMPERES
MIN – ECONOMY MODE
MAX – ECONOMY MODE MAX – POWER MODE
0
40
60
80
100
0 100 200 300 400 500
DC V
OLTS
DC AMPERES
MIN – ECONOMY MODE
350A – ECONOMY MODE
MAX – POWER MODE
Performance Data
2
Specifications (Subject to change without notice.)
Engine Specifications (Engine warranted separately by the engine manufacturer.)EngineBrand
MitsubishiS4L2
Features
EPA Tier 4i compliant, indirect-injected, liquid-cooled engine. Right-side service accesswith intervals of 500 hours for oil and filters.
HP
35
Type
4-cylinder, industrial,liquid-cooled, diesel
Engine Speeds
Idle: 1500 RPM Weld: 1800 RPMGouge: 3000 RPM
Capacities
Fuel: 43.5 L (11.5 gal.)Oil: 6 L (6.3 qt.)Coolant: 9.5 L (10 qt.)
Automatic EngineShutdown
Low Oil Pressure, High CoolantTemperature, Low Fuel Level
WeldMode
CC/DC(Stick/TIG)
CV/DC(FCAW)
CC/DC(CAC-A)
Weld OutputRange
20 – 450 A
14 – 40 V
40– 500 A
Weld Output Ratedat 40˚ C (104˚ F)
300 A, 32 VDC, 100% Duty Cycle450 A, 30 VDC, 40% Duty Cycle
300 A, 28 VDC, 100% Duty Cycle450 A, 30 VDC, 40% Duty Cycle
400 A, 36 VDC, 100% Duty Cycle500 A, 30 VDC, 40% Duty Cycle
Max. Open-CircuitVoltage
85
Generator Power Output Rated at 40˚ C (104˚ F)
Peak: 5500 watts Continuous: 4000 watts, 1-phase, 36/18 A, 120/240 VAC, 50/60 Hz
Dimensions
H: 813 mm (32 in.)W: 667 mm (26.25 in.)D: 1422 mm (56 in.)
Weight(without fuel)*
Net: 494 kg (1090 lb.)Ship: 517 kg (1140 lb.)
Sound Levels at Rated Output, 7 m (23 ft.)
Economy Mode:71.5 dB (96 Lwa)Power Mode:81.5 dB (106 Lwa)
Meets NEMA and IEC output ratings. *Additional 43 kg (95 lb.) when fuel tank is full.
Function Guide 1. Optional Self-Calibrating Digital Weld
Meters with Fault Code Indication (order #195 289) display preset or actualweld parameters.
2. Weld Process Select Switch
3. Amperage/Voltage Adjust Control
4. 14-pin Receptacle* for simple connectionof remote controls. It features Auto RemoteSense™ which automatically switches frompanel to remote amperage/voltage (A/V)control with remote connected. Eliminatesconfusion of the panel/remote A/V switch.
5. Weatherproof Lexan® Nameplate is superdurable and resists cracking and fading.Color coded controls for ease of operation.
6. Meter Maintenance Displays show fuellevel, engine hours, oil change interval andhi temp/low pressure/low fuel shutdowninformation.
Low Fuel Shutdown shuts engine off priorto running out of fuel to prevent loss of fuelin the system, and make restarts easy.Display will read noFUEL. Turn the machineoff, add fuel, and restart.
7. Engine Control Switch is used to start andstop the engine and select power range.Auto-Idle is standard.
8. Glow Plugs assist in cold weather starting.
9. Receptacle and Circuit Breaker Panel
10. CAC-A Positive (+) Gouging OutputTerminal
11. Stick/TIG/FCAW Positive (+) Weld OutputTerminal
12. Negative (-) Weld Output Terminal
*Controls only amperage or voltage on the Big Blue 500X Eco Pro—electrode always hot.
12
10
11
9
8
6
7
1
2
4
3
5
3
FCAW Position makes it easy torun most flux-cored wires up to 2 mm (5/64 in.) in diameter.
CAC-A/Stick Position providesexcellent arc characteristics andmakes welding easy. Utilizes Arc-Drive™ to focus the arc andprevent electrode from going outand Hot Start™ for positive arcstarts to make it easy to start alltypes of electrodes.
Scratch Start TIG Position.
240 V, 16 A AC Receptacle
Earth LeakageCircuit Breaker
120 V, 20 A AC Receptacle
with Ground Fault
120 V, 16 A AC Receptacle
4
Rigorous Testing for Tough,Real-World ConditionsTo prove our machines go to thelimit, Miller industrial enginedrives are put to the test in veryextreme environmental conditions.
• Airborne dust and sand.Critical components areexposed to abusive airborneparticles in a special testingchamber for weeks, helpingmake sure they’ll operate whilefacing extreme levels of dirt,dust or sand on the jobsite.
• Humidity and corrosion.Inside our Houston testingroom, critical components are subjected to extendedmoisture and corrosive saltexposure to ensure they’ll run even when exposed to humidclimates, corrosive coastal environments, and driving rain.
• Temperature extremes. Miller industrial engine drives are tested to ensure performance in scorching heat. All Millerengine-driven machines are weld rated at 40 degrees Celsius,but actual tests are conducted up to 50 degrees Celsius toassure 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 toensure they’ll withstand the stresses that can shut downcompetitive machines.
• Continuous operation. Miller industrial engine drives run dayand night, in all weather conditions, to assure they’ll performwithout interruption in the field.
Superior Circuit Board DesignOur critical circuit boards are engineered to carry low power andlow heat to reduce thermal stress and minimize expansion andcontraction. In contrast, our competitor’s boards carryhighpower and high heat, making them more vulnerable to failure.
What Makes Miller® Industrial Engine Drives So ?
“The Vault” Makes Upgrading to Miller® CC/CV UnitsWorry-FreeConcerns with circuit board reliability have resulted in some operators steering clear of CC/CV welder/generators — eventhough they offer a superior arc and multiple welding processes.Miller circuit board reliability isn’t a concern since all Big Bluemultiprocess industrial engine drives feature the Vault.
Created out of two aluminum halves sealed with silicone, as wellas watertight harness connections, the Vault provides a cleancircuit board environment, protecting the electronics — andcontrolling output — in heavy industrial applications. No othercompetitor protects their electronics with a sealed vault, leavingcritical circuit boards exposed to harsh elements that can disruptthe machine’s electronics, and therefore, its operation.
Why Industrial Engine Drive Customers Choose Miller®
The ultimate test of Miller’s reliability is how it performs in thefield. The quote on the left provides a glimpse of how Millerindustrial engine drives perform for customers. Read the full stories, and many others demonstrating Miller’s superiorreliability, at MillerWelds.com.
“The Big Blue 500X EcoPro reduced our fuel costsby about six liters a day or more than 120 liters amonth, while its smallersize and lighter weight hasdecreased transportationcosts. Plus, its controls are very easy to use, and the stable,smooth arc quality has decreased the need for rework. We’renow more productive and cost efficient.”
Mr. Frank Vucic, Structure SuperintendentMcConnell Dowell, South East Asia PTE LTD
“It’s much quieter than our previous machine, making it easier to communicate on the jobsite, reducing operator fatigue anddecreasing noise levels in the surrounding communities.”
Mr. RGS Nair, Welding Foreman of QCON
5
International Plugs#255 419 Field 1-Phase, 120 VAC, 16 A plug#255 416 Field 1-Phase, 240 VAC, 16 A plug
Cold Weather Starting Aid #300 664 Field120 V block heater. Note: All models come standard with preheaters (glow plugs).
Engine Filter Kit #252 782 Field Includes all filters required for proper enginemaintenance. Oil filter, primary and secondaryfuel filter, and primary air filter.
Spark Arrestor (Muffler) Kit #300 585 FieldPrevents particles from leaving the muffler thatcould potentially start a fire.
FA-1D Lockable Flame ArrestorFuel Cap #043 947 FieldFuel cap can be padlocked toprevent vandalism. A built-in flamearrestor prevents flames or sparksfrom entering the fuel tank.
Chalwyn Safety Valve #300 576 FieldShuts off air flow to the engine to prevent over-speed condition. Required on many petroleumjobsites, this valve provides both manual andautomatic operation giving you two methods ofoperation to meet jobsite compliance standards.
Protective Cover #195 301 FieldBlue water-resistant cover with Miller logoresists stains and mildew, and protects thefinish of your welder.
Stick (SMAW) WeldingNo. 2 Stick Cable Set, 4.6 m (15 ft.) #195 196Consists of 4.6-m (15 ft.) No. 2 electrode cablewith holder, and 4.6-m (15 ft.) work cable withclamp. 200 A, 100% duty cycle.
No. 2 Stick Cable Set, 15 m (50 ft.) #300 836Consists of 15-m (50 ft.) No. 2 electrode cablewith holder, and 15-m (50 ft.) work cable withclamp. 200 A, 100% duty cycle.
2/0 Stick Cable Set, 15 m (50 ft.) #173 851Consists of 15-m (50 ft.) 2/0 electrode cablewith holder, and 15-m (50 ft.) work cable withclamp. 350 A, 100% duty cycle.
2/0 Stick Cable Set, 30.5/15 m (100/50 ft.)#043 952Consists of 30.5-m (100 ft.) 2/0 electrode cablewith holder, and 15-m (50 ft.) work cable withclamp. 300 A, 100% duty cycle.
MIG (GMAW) or Flux-Cored (FCAW)Millermatic® Passport®
Plus #907 401Portable, all-in-one MIG package features ultimate arc performance,self-contained gas bottle,and flexibility to plug into
115 or 230 V power with Miller exclusive Multi-Voltage Plug. See Lit. Index No. DC/12.53.
SuitCase® X-TREME™
8VS #300 656SuitCase® X-TREME™
12VS #300 659Lightweight, voltage-sensing wire feedersinclude secondary
contactor and gas valve. Requires drive roll kit.See Lit. Index No. M/6.41.
MIG (GMAW)/Flux-Cored (FCAW) GunsMiller produces a com plete line of dependableMIG guns. See Lit. Index Nos. AY/15.0, AY/16.0and AY/17.0.
TIG (GTAW) WeldingHF-251 Series#042 388 HF-251D-1, 115 VAC #042 387 HF-251-2, 230 VAC High-frequency arc starter andstabilizer. CorrespondingSecondary Contactors listed
above right are recommended when using HFSeries with Eco Pro engine drives. SeeAccessory Lit. Index No. AY/5.0.
Secondary Contactor Kit#041 969 Field. For HF-251D-1 #041 906 Field. For HF-251-2For power sources without a contactor. Mountsinside HF-251 cabinet.
Plasma Cutting
Spectrum® 375 X-TREME™ #907 529See Lit. Index No. PC/9.2.Spectrum® 625 X-TREME™
#907 531 with 3.7-m (12 ft.) torch#907 531-00-1 with 6-m (20 ft.) torchSee Lit. Index No. PC/9.6.The Spectrum 375 X-TREME and 625 X-TREMEcome complete with protective X-CASE™
(not shown).
Remote ControlsWireless Remote FootControl* #300 429For remote current,voltage and contactorcontrol. Receiver plugsdirectly into the 14-pin
receptacle of Miller machine. 27.4-m (90 ft.)operating range. Requires Wireless Antenna Kit#300 749.
Wireless Remote HandControl* #300 430For remote current or voltagecontrol. Receiver plugsdirectly into the 14-pinreceptacle of Miller machine.
91.4-m (300 ft.) operating range. RequiresWireless Antenna Kit #300 749.
Wireless Antenna Kit #300 749Required for Pro Series engine drives. Optionalon other compatible Miller products whereimproved reception is desired.
RFCS-14 HD Foot Control* #194 744Heavy-duty foot control for current, voltage andcontactor control. Includes 6-m (20 ft.) cordand 14-pin plug.
RHC-14 Hand Control* #242 211 020Miniature hand control for remote current,voltage and contactor control. Dimensions: 102 x 102 x 82 mm (4 x 4 x 3.25 in.). Includes6-m (20 ft.) cord and 14-pin plug.
RCC-14 Remote Fingertip Control* #151 086Side-to-side rotary-motion fingertip controlfastens to TIG torch using two Velcro® straps.Includes 8-m (26.5 ft.) cord and 14-pin plug.
Extension Cables for 14-Pin Remote Controls#242 208 025 7.6 m (25 ft.)#242 208 050 15.2 m (50 ft.)#242 208 080 24.4 m (80 ft.)
*Controls only amperage or voltage on the Big Blue 500X Eco Pro—electrode always hot.
Genuine Miller Accessories
6
4 West Four-Wheel Steerable Off-Road Trailer#042 801A heavy-duty 1166-kg (2570 lb.) capacity trailerdesigned for use in mines, quarries, and otherrough terrain. Has narrow 6.7-m (22 ft.) turningradius. Includes 76-mm (3 in.) 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 1202-kg (2650 lb.) capacity trailer. Weldedsteel tubing frame, heavy-duty axle with rollerbearing hubs and leaf-spring suspension.Includes jack stand and 50-mm (2 in.) ball hitch.HWY-224 also includes fenders and lights.Note: Trailer is shipped unassembled.
Cable Tree #043 826Provides an area to conveniently wrap weldcables and extension cords.
Dual Hitch #300 83150-mm (2 in.) ball hitch and 76-mm (3 in.)lunette eye in one reversible assembly.
4 holes F
Front Panel
C
ED
A B
Trailers and Hitches (Note: Trailers are shipped unassembled.)
Gross VehicleWeight Rating
1361 kg(3000 lb.)
1343 kg(2960 lb.)
Gross AxleWeight Rating
907 kg/axle (2000 lb./axle)
1588 kg(3500 lb.)
Height of Bed
540 mm(21.25 in.)
470 mm(18.5 in.)
RoadClearance
203 mm(8 in.)
191 mm(7.5 in.)
NetWeight
195 kg(430 lb.)
145 kg(320 lb.)
Track (Centerto center oftires)
1403 mm(55.25 in.)
1321 mm(52 in.)
Standard Tires(Standard ratingor P-size rating)
B78-13
B78-13
Dimensions
Length: 2311 mm (91 in.)*Width: 1556 mm (61.25 in.)
Length: 2667 mm (105 in.)Width:HWY–1511 mm (59.5 in.)** OFR–1484 mm (58.437 in.)
*Does not include tongue. **Width at outside of fenders.
Model
4 West
HWY-224OFR-224
NetPayload
1166 kg(2570 lb.)
1202 kg(2650 lb.)
Mounting Specifications
Trailer Specifications (Subject to change without notice.)
Height: 813 mm (32 in.)Width: 667 mm (26.25 in.)Depth: 1422 mm (56 in.)
A. 705 mm (27.75 in.)B. 667 mm (26.25 in.)C. 1321 mm (52 in.)D. 51 mm (2 in.)E. 1422 mm (56 in.)F. 14 mm (.562 in.) diameter
7
14-Pin PRHC-14Wireless Remote
Hand Control
Work
Electrode/CarbonRemote Control
OR
Work
Flux-Cored GunSuitCaseX-TREME8VS/12VS
Work
MIG GunMillermatic
Passport
Cutting Torch
Work
Spectrum
TIGTorch
Work
14-Pin
HF-251
Secondary ContactorRecommended
Plasma Basic EquipmentSpectrum® 375 X-TREME™ #907 529Spectrum® 625 X-TREME™
#907 531 with 3.7-m (12 ft.) torch#907 531-00-1 with 6-m (20 ft.) torch
Stick (SMAW) and Air Carbon Arc Cuttingand Gouging (CAC-A) Basic EquipmentPRHC-14 #195 511Wireless Remote Hand Control #300 430Wireless Antenna Kit #300 749
Flux-Cored (FCAW) Basic EquipmentSuitCase® X-TREME™ 8VS #300 656SuitCase® X-TREME™ 12VS #300 659
MIG (GMAW) Basic EquipmentMillermatic® Passport™ #907 401
Typical Installations
TIG (GTAW) Basic EquipmentHF-251D-1 #042 388HF-251-2 #042 387Secondary Contactor (Recommended)
#041 969 For HF-251D-1#041 906 For HF-251-2
Litho in USA
Distributed by:
Equipment and Options Stock No. Description Qty. Price
Big Blue® 500X Eco Pro #907 427 Base machine (CC/CV, Flux-Cored) #907 427-001 With Weld Meters and Spark Arrestor
Field AccessoriesDigital Weld Meter Kit #195 289 FieldInternational Plugs #255 419 Field. 1-phase, 120 V, 16 A #255 416 Field. 1-phase, 240 V, 16 ACold Weather Starting Aid #300 664 Field. 120 V block heaterEngine Filter Kit #252 782 Field. Includes air, oil and fuel filtersSpark Arrestor (Muffler) Kit #300 585 FieldFA-1D Lockable Flame Arrestor Fuel Cap #043 947 FieldChalwyn Safety Valve #300 576 FieldProtective Cover #195 301 Field
Stick Welding Leads See page 5
MIG/Flux-Cored Welding Millermatic® Passport® Plus #907 401 Includes gas bottle and MVP. See Lit. Index No. DC/12.53SuitCase® X-TREME™ 8VS #300 656 See Lit. Index No. M/6.41SuitCase® X-TREME™ 12VS #300 659 See Lit. Index No. M/6.41MIG (GMAW) and Flux-Cored (FCAW) Guns See Lit. Index Nos. AY/15.0, AY/16.0 and AY/17.0
TIG Welding HF-251 Series #042 388 HF-251D-1, 115 VAC. See Lit. Index No. AY/5.0(Secondary Contactor Recommended) #042 387 HF-251-2, 230 VAC. See Lit. Index No. AY/5.0Secondary Contactor Kit #041 969 Field. For HF-251D-1 #041 906 Field. For HF-251-2
Plasma Cutting Spectrum® 375 X-TREME™ #907 529 Includes X-CASE™. See Lit. Index No. PC/9.2Spectrum® 625 X-TREME™ #907 531 With 3.7-m (12 ft.) torch and X-CASE™. See Lit. Index No. PC/9.6 #907 531-00-1 With 6-m (20 ft.) torch and X-CASE™. See Lit. Index No. PC/9.6
Remote ControlsWireless Remote Foot Control #300 429 Amperage or voltage control only — electrode always hot. Requires Wireless Antenna KitWireless Remote Hand Control #300 430 Amperage or voltage control only — electrode always hot. Requires Wireless Antenna KitWireless Antenna Kit #300 749 Required for wireless remotes when using Pro Series engine drives RFCS-14 HD Foot Control #194 744 Amperage or voltage control only — electrode always hotRHC-14 Hand Control #242 211 020 Amperage or voltage control only — electrode always hotRCC-14 Remote Fingertip Control #151 086 Amperage or voltage control only — electrode always hotExtension Cables See page 5
Trailers and Hitches4 West Four-Wheel Steerable Trailer #042 801 Trailer with lunette eye, universal hitch and safety chains. For off-road useHWY-224 Trailer #043 805 Trailer with lights, fenders and 50-mm (2 in.) ball hitch. For highway useOFR-224 Trailer #043 802 Trailer with 50-mm (2 in.) ball hitch. For off-road useCable Tree #043 826 Trailer-mounted cable holder for HWY-224 or OFR-224 Dual Hitch #300 831 Combination 50-mm (2 in.) ball hitch and 76-mm (3 in.) lunette eye in one reversible assembly. For HWY-224 or OFR-224
Date: Total Quoted Price:
Ordering Information