Miller Big Blue 500 X CC - User Manual

Big Blue
®
500 X and 600 X
Diesel Engine-Driven
Welder/Generator
Issued April 2018 • Index No. EDX/10.11
Designed for fleet owners that
demand the ultimate in reliability
and performance.
Three-phase rotating field generator
efficiently produces smooth DC weld
output using 20 to 30 percent less
fuel than a rotating armature-type
DC generator.
Enclosed robust case design
protects internal components from
impact and allows air flow to cool
and prolong the life of the engine.
Also reduces sound levels.
Quick and easy maintenance
with single-side access to oil level
check, oil fill, oil filter, fuel filter and
air cleaner.
Remote toolless oil drain allows oil
to be drained without getting under
the engine and reduces the chance
of oil spillage.
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.
HD powder coat with zinc-rich
primer protects sheet metal from rust
and corrosion.
Heavy-duty low-speed industrial
diesel engines are designed, built
and proven to operate over 10,000
hours before the first basic overhaul.
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 of fuel, making restarts easy.
Arc-Drive
™
makes welding easy.
Automatically enhances stick
welding, especially on pipe, by
focusing the arc and preventing the
electrode from going out.
Weatherproof Lexan
®
nameplate
resists cracking and fading, and is
color coded for ease of operation.
GFCI receptacle as required on
most jobsites to protect oper ators
from electrical hazards.
CSA, IEC and NEMA compliant for
welders. Degree of protection
provided by enclosure IP23.
Welder/generator is warranted by Miller for three years, parts and labor.
Engine is warranted separately by engine manufacturer.
Heavy Industrial
Applications
Heavy construction
Structural steel
Maintenance and repair rigs
Mining maintenance
Process piping
Sheet metal
Processes
Stick (SMAW)
DC TIG (GTAW)
Air carbon arc (CAC-A)
500 X
Rated: 8 mm (5/16 in.) carbons
Capable: 9.5 mm (3/8 in.) carbons
600 X
Rated: 9.5 mm (3/8 in.) carbons
Output Range
500 X CC DC stick: 55–500 A, DC/TIG: 55–500 A
600 X CC DC stick: 55–600 A, DC/TIG: 55–600 A
Generator Output Rated at 104°F (40°C)
5,500 watts peak, 4,000 watts continuous
Big Blue 600 X CC shown.
Quick
Specs
Miller Electric Mfg. LLC
An ITW Welding Company
1635 West Spencer Street
P.O. Box 1079
Appleton, WI 54912-1079 USA
MillerWelds.comEquipment Sales US and Canada
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125

Summary

Big Blue 500 X and 600 X Welder;Generator Overview

Quick Specs and Applications

Summarizes applications like construction, repair, piping, and sheet metal.

Processes and Output Range

Details welding processes (Stick, TIG, CAC-A) and output specifications for 500X/600X models.

Key Features and Benefits

Highlights efficiency, durability, ease of maintenance, and enhanced welding features.

Engine and Control Systems

Covers engine details, operator interface, arc control, and compliance standards.

Specifications and Control Panel

Model Specifications Table

Provides detailed data on weld output, duty cycle, dimensions, and weight for Big Blue 500X and 600X models.

Control Panel Components

Identifies and describes each control and indicator on the machine's front panel.

Additional Features

Explains features like rheostat control, stick/TIG switch functionality, and remote amperage adjustment.

Performance Data Analysis

Volt;Amp Curves - Stick Mode

Displays DC voltage and amperage relationships for both 500X and 600X models in stick welding mode.

Fuel Consumption Curve

Illustrates fuel consumption rates in liters per hour versus DC weld amperes at 100% duty cycle.

Duty Cycle Curve

Shows weld amperes versus percentage of duty cycle for 500X and 600X models.

Generator Power Curve

Depicts AC output in amperes at 240V and 120V modes versus AC volts.

Engine Specifications and Options

Engine Specifications Table

Compares engine models (Perkins, Deutz) by HP, type, speeds, capacities, and automatic shutdowns.

Genuine Miller Options

Lists available optional kits for enhancing machine functionality and monitoring.

Genuine Miller Accessories

Welding Accessories

Details accessories for engine maintenance, safety, and cable management.

Welding Process Accessories

Covers protective covers, weld leads, TIG welding equipment, plasma cutters, and remote controls.

Trailers, Hitches, and Mounting

Trailers and Hitches

Details the 4 West and HWY-225 trailers, and the Cable Tree accessory.

Trailer Specifications Table

Provides specifications for Gross Axle Weight, Gross Vehicle Weight, Net Payload, dimensions, and tires.

Mounting Specifications

Shows dimensions and hole patterns for machine mounting, including key measurements.

Typical Installations

Electrode Hot Installations

Illustrates basic Stick (SMAW) and Scratch Start TIG (GTAW) welding configurations.

Remote On;Off Required Installations

Demonstrates Stick (SMAW) welding with remote control and Plasma cutting setups.

Ordering Information

Equipment and Factory Options

Lists available welder models and factory-installed options with stock numbers.

Field Accessories

Details accessories available for field installation, including meters and switches.

Welding and Plasma Accessories

Lists accessories for stick welding, TIG welding, plasma cutting, and remote controls.

Trailers and Hitches

Lists available trailers and related hitch accessories with stock numbers.

Miller Big Blue 500 X CC Specifications