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Miller Big Blue 500X
Miller Big Blue 500X
Engine-Driven
Welder/Generator
Miller Electric Mfg. Co. Equipment Sales US and Canada Web Site
An Illinois Tool Works Company Phone: 866-931-9730 www.MillerWelds.com
1635 West Spencer Street FAX: 800-637-2315
Appleton, WI 54914 USA International Phone: 920-735-4554
International FAX: 920-735-4125
Big Blue 500 X and 600 X CC Specifications
®
(Subject to change without notice.)
Weld Max. Open-
Welding Output Weld Output Rated at Circuit Generator Output Weight
Model Mode Range 104˚F (40˚C) Voltage Rated at 104˚F (40˚C) Dimensions** (without fuel)***
Big Blue CC/DC 55 – 500 A 400 A at 36 V (14.4 kW),* 95 Peak: 5500 watts H: 43 in Perkins 404D.22:
500 X CC 100% Duty Cycle Continuous: 4000 watts, (1092 mm) 1545 lb (701 kg)
450 A at 38 V (17.1 kW),* 1-phase, 34/17 A, W: 28-1/2 in Deutz D2011L03i:
60% Duty Cycle 120/240 VAC, 50/60 Hz (724 mm) 1655 lb (751 kg)
while welding D: 64-7/16 in
500 A at 30 V (15 kW),
40% Duty Cycle (1637 mm)
Big Blue 55 – 600 A 500 A at 40 V (20 kW),* Deutz D2011L04i:
600 X CC 100% Duty Cycle 1695 lb (769 kg)
550 A at 34 V (18.7 kW), Deutz D912L03:
60% Duty Cycle 1785 lb (810 kg)
600 A at 30 V (18 kW),
40% Duty Cycle
*NEMA EW1 (ANSI C87.1) Class (1) output ratings. **Additional 7 in (178 mm) to top of exhaust. ***Additional 190 lb (86 kg) when fuel tank is full.
1. DC Ammeter*
1
2. DC Voltmeter*
9
2 3. Amperage Adjust Control
10
11 4. Amperage Range Switch
3
5. Amperage Adjust Switch and
4 12
Remote Amperage Adjust Receptacle
6. Stick/TIG Selector Switch
7. Earth Leakage Circuit Breaker
OFF
8. 230 VAC, 16 A Pin and Sleeve Receptacle
9. Fuel Gauge/Hour Meter/Oil Change
RUN/IDLE
RUN
5 START
Interval/Engine Shutdown Indicator
13
6 14 10. Engine Oil Pressure Gauge
11. Battery/Voltmeter*
12. Engine Coolant Temperature Gauge
13. Engine Control Switch
7 14. Starting Aid Switch
15
8 (standard on Perkins model)
15. 120 VAC, 20 A GFCI Duplex Receptacle
16. Polarity Switch*
16 *Optional.
Additional Features
Proven, rugged rheostat A Stick/TIG switch optimizes Provisions are provided to plug
control technology that has open-circuit voltage for Stick a RHC3GD34A remote control
been in Miller engine drives for welding and allows the open- that will allow precise adjust-
over 60 years. Contains no circuit voltage to be lowered ment of amperage without
printed control boards. for scratch start TIG welding. walking back to the machine.
2
Big Blue 500 X and 600 X CC/CV Specifications
®
(Subject to change without notice.)
Weld Max. Open-
Welding Output Weld Output Rated at Circuit Generator Output Weight
Model Mode Range 104˚F (40˚C) Voltage Rated at 104˚F (40˚C) Dimensions** (without fuel)***
Big Blue CC/DC 15 – 550 A 400 A at 36 V (14.4 kW),* 95 Peak: 5500 watts H: 43 in Perkins 404D.22:
500 X CC/CV CV/DC 14 – 40 V 100% Duty Cycle Continuous: 4000 watts, (1092 mm) 1545 lb (701 kg)
450 A at 38 V (17.1 kW),* 1-phase, 34/17 A, W: 28-1/2 in Deutz D2011L03i:
60% Duty Cycle 120/240 VAC, 50/60 Hz (724 mm) 1655 lb (751 kg)
while welding D: 64-7/16 in
500 A at 34 V (17 kW),
40% Duty Cycle (1637 mm)
Big Blue 20 – 600 A 500 A at 40 V (20 kW),* Deutz D2011L04i:
600 X CC/CV 14 – 40 V 100% Duty Cycle 1695 lb (769 kg)
550 A at 42 V (23.1 kW), Deutz D912L03:
60% Duty Cycle 1785 lb (810 kg)
600 A at 34 V (20.4 kW),
40% Duty Cycle
*NEMA EW1 (ANSI C87.1) Class (1) output ratings. **Additional 7 in (178 mm) to top of exhaust. ***Additional 190 lb (86 kg) when fuel tank is full.
1 1. DC Ammeter
9 2. DC Voltmeter
2 10 3. Amperage/Voltage Adjust Control
3 11 4. Amperage Range Switch
4 12 5. Amperage/Voltage Adjust Switch and
Remote Amperage/Voltage Adjust Receptacle
6. Process/Contactor Selector Switch
7. Earth Leakage Circuit Breaker
5 OFF 8. 230 VAC, 16 A Pin and Sleeve Receptacle
6 RUN/IDLE
RUN
9. Fuel Gauge/Hour Meter/Oil Change Interval
13 Engine Shutdown Indicator
START
Additional Features
One MIG welding range allows precise voltage boards carry high power and high heat, making
control for welding with .023 –.120 in them more vulnerable to failure.
(0.6 – 3.2 mm) wires.
“The Vault” Makes Upgrading to Miller CC/CV
A multi-colored process selector control Units Worry-Free
allows quick and easy process changes without Concerns with circuit board reliability have
having to use multiple switches. resulted in some operators steering clear of
CC/CV welder/generators — even though they
14-pin remote control allows precise adjustment offer a superior arc and multiple welding board environment, protecting the electronics
of amperage or voltage, along with contactor processes. Miller’s circuit board reliability isn’t — and controlling output — in heavy industrial
control, without walking back to the machine. a concern since all Big Blue multiprocess applications. No other competitor protects their
industrial engine drives feature the Vault. electronics with a sealed vault, leaving critical
The Vault — Superior Circuit Board Design
Miller’s critical circuit boards are engineered Created out of two aluminum halves sealed circuit boards exposed to harsh elements that
to carry low power and low heat to reduce with silicone, as well as watertight harness can disrupt the machine’s electronics, and
thermal stress and minimize expansion and connections, the Vault provides a clean circuit therefore, its operation.
contraction. In contrast, our competitor’s
3
Big Blue 500 X and 600 X CC Performance Data
®
500 X CC 600 X CC
VOLT/AMP CURVES – STICK MODE VOLT/AMP CURVES – STICK MODE GENERATOR POWER CURVE
100 100 150 300
Ranges Ranges
80 230 – Max 80 300 – Max 125 250 4 kW 5.5 kW
170 – 365 185 – 425
AC VOLTS
110 – 225 125 – 320 100 200
DC VOLTS
DC VOLTS
60 70 – 130 60 85 – 190
55 – 85 65 – 90
75 150
40 40
50 100
20 20
25 50
0 0 0 0
0 100 200 300 400 500 600 700 800 900 1000 0 100 200 300 400 500 600 700 800 900 1000 0 5 10 15 20 25 30
DC AMPERES DC AMPERES AC AMPERES IN 240 V MODE
0 10 20 30 40 50 60
FUEL CONSUMPTION CURVE DUTY CYCLE CURVE AC AMPERES IN 120 V MODE
2.00 1000
1.75 800
WELD AMPERES
600 600 X
1.50
US GAL/HR.
500
1.25 400
500 X
1.00 600 X 300
1800 RPM 250
0.75
500 X 200
0.50
600 X IDLE 150
0.25 500 X IDLE
0.00 100
0 50 100 150 200 250 300 350 400 450 500 10 15 20 25 30 40 50 60 80 100
DC WELD AMPERES AT 100% DUTY CYCLE % DUTY CYCLE
0 0 100
0 100 200 300 400 500 600 700 800 900 1000 0 100 200 300 400 500 600 700 800 900 1000 10 15 20 25 30 40 50 60 80 100
DC AMPERES DC AMPERES % DUTY CYCLE
DC VOLTS
60 60 1.25
MAX
1.00 600 X
40 40 1800 RPM
MAX 0.75
500 X
20 20 0.50
MIN MIN
600 X IDLE
0.25 500 X IDLE
0 0
0 100 200 300 400 500 600 700 800 900 1000 0 100 200 300 400 500 600 700 800 900 1000 0.00
0 50 100 150 200 250 300 350 400 450 500
DC AMPERES DC AMPERES
DC WELD AMPERES AT 100% DUTY CYCLE
500 X CC/CV 600 X CC/CV
VOLT/AMP CURVES – TIG MODE VOLT/AMP CURVES – TIG MODE
100 100
Ranges Ranges
80 60 – 365 80 50 – 440
35 – 250 35 – 320
DC VOLTS
DC VOLTS
25 – 155 25 – 215
60 15 – 75 60 15 – 115
40 40
20 20
0 0
0 100 200 300 400 500 0 100 200 300 400 500
DC AMPERES DC AMPERES
4
Engine Specifications (Subject to change without notice.)
Engine Automatic
Engine Speeds Engine
Model Brand Features HP Type (RPM) Capacities Shutdowns
Big Perkins Tier 4i, EPA-certified, indirect-injected, liquid-cooled engine 32.6 4-cylinder, Weld: 1800 Fuel: 25 gal (95 L) Low Oil Pressure,
Blue 404D.22 with full load sound levels of 73.2 dB @ 7 m (98 Lwa). industrial, Idle: 1235 Oil: 9 qt (8.5 L) High Coolant
500 X Right-side service access with service intervals of 500 hours liquid-cooled Coolant: 9 qt (8.5 L) Temperature,
for oil and filters. diesel Low Fuel Level
Deutz Tier 4i, EPA-certified, direct-injected, air/oil-cooled engine 32.0 3-cylinder, Weld: 1800 Fuel: 25 gal (95 L) Low Oil Pressure,
D2011L03i with full load sound levels of 76.8 dB @ 7 m (101.7 Lwa). industrial, Idle: 1235 Oil: 6.2 qt (5.9 L) High Coolant
Right-side service access with service intervals of 1000 air/oil-cooled Coolant: Temperature,
hours for oil and filters. Approved underground operation diesel Integrated oil Low Fuel Level
with the purchase of a MSHA (30 CFR part 7) certificate.
Big Deutz Tier 4i, EPA-certified, direct-injected, air/oil-cooled engine 48.6 4-cylinder, Weld: 1800 Fuel: 25 gal (95 L) Low Oil Pressure,
Blue D2011L04i with full load sound levels of 76 dB @ 7 m (101 Lwa). industrial, Idle: 1235 Oil: 9 qt (8.5 L) High Coolant
600 X Right-side service access with service intervals of 1000 air/oil-cooled Coolant: Temperature,
hours for oil and filters. Approved underground operation diesel Integrated oil Low Fuel Level
with the purchase of a MSHA (30 CFR part 7) certificate.
Deutz The legendary Tier I, EPA-certified, direct-injected, air-cooled 41.5 3-cylinder, Weld: 1800 Fuel: 25 gal (95 L) Low Oil Pressure,
D912L03 engine with full load sound levels of 81 dB @ 7 m (106 Lwa). industrial, Idle: N/A Oil: 9 qt (8.5 L) High Coolant
Right-side service access with service intervals of 500 hours air-cooled Coolant: Air Temperature,
for oil and filters. diesel Low Fuel Level
RUN/IDLE
RUN
Perkins. 120 volt block heater.
Installation time: 35 minutes START
5
Genuine Miller Accessories
FA-1D Lockable Flame Arrestor Stick (SMAW) Welding
Fuel Cap #043 947 Field
Fuel cap can be padlocked to Weld Leads
prevent vandalism. A built-in #173 851 2/0, 350 A, 100% duty cycle,
flame arrestor prevents flames or 50 ft stinger, 50 ft work cable
sparks from entering the fuel tank. #043 952 2/0, 300 A, 100% duty cycle,
100 ft stinger, 50 ft work cable
Spark Arrestor
Muffler Kit SuitCase® 8RC Wire Feeder #951 186
#195 012 Field Plasma Cutting SuitCase® 12RC Wire Feeder #951 188
Prevents particles Lightweight and flexible enough to run a
from leaving the muffler that could variety of wires up to .062 in diameter.
potentially start a fire. Mandatory when Includes remote voltage control and drive
operating on California grasslands, brush, roll kit. See Lit. Index No. M/6.5.
or forest-covered land, and in all National MIG (GMAW)/Flux Cored (FCAW) Guns
Forests. For other areas, check your state Miller produces a complete line of
and local laws. Meets US Forest Service Spectrum® 375 X-TREME™ #907 339 dependable MIG guns. See Lit. Index Nos.
standard 5100-1B. See Lit. Index No. PC/9.2. AY/15.0, AY/16.0 and AY/17.0.
Spectrum® 625 X-TREME™ #907 404
Vandalism Lockout Kit Spoolmatic® 30A
See Lit. Index No. PC/9.6.
#195 118 Field Spool Gun
Lockable hinged steel Spectrum® 875 #907 390-01-1
See Lit. Index No. PC/9.8. #130 831
panels cover and protect Air-cooled, 200-amp,
name plate gauges and The Spectrum 375 X-TREME and 625
1-lb spool gun for
ignition switch (padlock X-TREME come complete with protective
aluminum MIG. See Lit. Index No. M/1.73.
included). Also includes X-CASE™ (not shown).
engine compartment door WC-24 Control #137 549
lock and key. Use with Spoolmatic 30A.
MIG (GMAW) or Flux Cored (FCAW)
Cable Holder #043 946 Millermatic® XR™ Wire Feeders and Guns
Saddle-bag-style cable Passport® Plus Push-pull system designed to handle
holder. Convenient wrap- #907 401 difficult-to-feed soft alloy wires such as
around storage of coiled Portable, all-in-one aluminum. See Lit. Index No. M/1.7,
cable for transportation. MIG package M/1.71, and M/1.73.
Stores 100 ft of 2/0 cable features ultimate
on each side. arc performance,
self-contained gas TIG (GTAW) Welding
Note: For best results do not weld when cable is coiled!
Canvas cover cannot be used with cable holder. bottle, and flexibility to plug into 115 or 230 V
power with Miller exclusive Multi-Voltage Dynasty® 200 Series
Roll Cage/Drip Pan Plug. See Lit. Index No. DC/12.53. For premium portable
#194 918 Field AC/DC TIG arc quality.
Heavy-duty galvanized See Lit. Index No.
steel structure AD/4.8.
designed to protect the
machine. The roll cage
meets offshore oil
platform requirements with a drip pan and HF-251 Series
drain plug along with a heavy-duty lift eye. #042 388
SuitCase® X-TREME™ 8VS Wire Feeder HF-251D-1, 115 VAC
Canvas Cover (Blue) #951 182 #042 387
#194 683 Field SuitCase® X-TREME™ 12VS Wire Feeder HF-251D-2, 230 VAC
Attractive, waterproof #951 184 High-frequency arc
canvas cover resists Lightweight, voltage-sensing wire feeders starter and stabilizer. See
stains and mildew, include secondary contactor, gas valve and Accessory Lit. Index No. AY/5.0.
and protects the drive roll kit. See Lit. Index No. M/6.41.
finish of your welder.
Note: Canvas cover cannot be used with cable holder.
6
Genuine Miller Accessories (Continued)
RCCS-14 Remote
Remote Controls (CC/CV models) Contactor and
RHC-14 Hand Control Current Control
RMLS-14 #129 337
#242 211 020 #043 688
Fingertip momentary- and maintained-
Miniature hand control for Up-and-down rotary-motion fingertip control
contact rocker switch for contactor control.
remote current and contactor fastens to TIG torch using two Velcro®
Push forward for maintained contact and
control. Dimensions: 4 x 4 x straps. Includes 28 ft (8.5 m) control cord.
back for momentary contact. Includes 20 ft
3-1/4 in (102 x 102 x 82 mm). Includes 20 ft (6 m) cord and 14-pin plug. Extension Cords for 14-Pin Remote Controls
(6 m) cord and 14-pin plug.
#122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (22.9 m)
4 West Four-Wheel Steerable HWY-224 Trailer #043 805 For highway use. HWY-430 Tandem Axle Trailer #043 806
Off-Road Trailer #042 801 OFR-224 Trailer #043 802 For off-road use. Smooth riding with 3750 lb (1701 kg) capacity.
A heavy-duty 2570 lb (1166 kg) capacity trailer A 2650 lb (1202 kg) capacity trailer. Welded Includes hand-operated parking brake, hydraulic
designed for use in mines, quarries, and other steel tubing frame, heavy-duty axle with roller brake system, and a break-away device to lock
rough terrain. Has narrow 22 ft (6.7 m) turning bearing hubs and leaf-spring suspension. brakes if the trailer comes loose. Includes jack
radius. Includes 3 in lunette eye, universal hitch Includes jack stand, 2 in (50 mm) ball hitch. stand, fenders and lights. (Hitch must be
and safety chains. HWY-224 also includes fenders and lights. ordered separately.)
Note: Trailer is shipped unassembled. Note: Trailer is shipped unassembled. Note: Some assembly required.
Cable Tree #043 826 Cable Tree #043 826
Provides an area to conveniently wrap weld Provides an area to conveniently wrap weld
cables and extension cords. cables and extension cords.
Lunette Eye 2-1/2 in (64 mm) #043 824 Ball Hitch 2 in (50 mm) #043 864
Lunette Eye 3 in (76 mm) #043 863
7
Ordering Information
Equipment and Factory Options Stock No. Description Qty. Price
Big Blue® 500 X CC #907 185 Deutz D2011L03i with engine gauges and dry battery
#907 187 Perkins 404D.22 with engine gauges and dry battery
#907 187-02-1 Perkins 404D.22 with engine gauges, dry battery, weld meters and polarity switch
Big Blue® 500 X CC/CV #907 184 Deutz D2011L03i with engine gauges and dry battery
#907 186 Perkins 404D.22 with engine gauges and dry battery
#907 186-02-1 Perkins 404D.22 with engine gauges, dry battery, weld meters and polarity switch
Big Blue® 600 X CC #907 193 Deutz D2011L04i with engine gauges and dry battery
#907 189 Deutz D912L03 with engine gauges and dry battery
#907 189-01-2 Deutz D912L03 with engine gauges, and wet battery
Big Blue® 600 X CC/CV #907 192 Deutz D2011L04i with engine gauges and dry battery
#907 188 Deutz D912L03 with engine gauges and dry battery
Field Kit Accessories
Weld Ammeter and Voltmeter #195 131 For all models, analog welding meters
Polarity Reversing Switch #043 942 For all models, DC polarity switch
#195 095 For all models, AC/DC polarity switch
Cold Weather Starting Aids #195 056 Perkins, 120 volt block heater
#195 307 Deutz D2011L03i and D2011L04i, 12 volt intake manifold heater
#195 086 Deutz D2011L03i and D2011L04i, 120 volt oil pan heater
Automatic Idle Kit #043 938 Perkins 404C.22, automatic idler
#300 510 Perkins 404D.22, automatic idler
#043 937 Deutz D2011L03i and D2011L04i, automatic idler
Battery Voltmeter #195 454 For all models, analog
Lockable Fuel Cap Flame Arrestor #043 947 For all models, padlock not included
Spark Arrestor Muffler #195 012 For all models, horizontal externally mounted
Vandalism Lockout Kit #195 118 For all models, lockable front control panel and engine compartment
Cable Holder #043 946 For all models, stores up to 200 ft (61 m) of 2/0 weld cable
Roll Cage/Drip Pan #194 918 For all models, meets offshore oil platform requirements
Protective Cover #194 683 For all models, will not work with cable holder accessory
Stick Accessories
Accessory Kits #173 851 2/0, 350 A, 100% duty cycle, 50 ft (15 m) stinger, 50 ft (15 m) work clamp
#043 952 2/0, 300 A, 100% duty cycle, 100 ft (30.5 m) stinger, 50 ft (15 m) work clamp
MIG/Flux Cored Accessories
Millermatic® Passport® Plus #907 401 Includes gas bottle and MVP. See Lit. Index No. DC/12.53
SuitCase® X-TREME™ 8VS and 12VS #951 182 /#951 184 See Lit Index No. M/6.41
SuitCase® 8RC and 12RC #951 186 /#951 188 See Lit Index No. M/6.5
MIG (GMAW)/Flux Cored (FCAW) Guns See Lit Index Nos. AY/15.0, AY/16.0 and AY/17.0
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
TIG Accessories
Dynasty® 200 Series See Lit Index No. AD/4.8
High Frequency Arc Starters See Lit. Index No. AY/5.0
Remote Controls
RHC-3GD34A #041 122 CC models only, hand control
RHC-14 #242 211 020 CC/CV models only, amperage or voltage control
RFCS-14 HD #194 744 CC/CV models only, foot control
RMLS-14 #129 337 CC/CV models only, momentary and maintained contact switch
RCC-14 #151 086 CC/CV models only, fingertip control
RCCS-14 #043 688 CC/CV models only, fingertip control
Remote Control Extension Cords See page 6
Trailers and Hitches See page 7
Distributed by:
Litho in USA