Miller Electric Big Blue 400P, Big Blue 500 X manual Use switch to select weld amperage range

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7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)

Engine Starting Controls

1 Starting Aid Switch

Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing).

2 Engine Control Switch

Use switch to start engine, select engine speed ( if unit has auto idle option), and stop engine.

In Run position, engine runs at weld/power speed. In Auto position (optional), engine runs at idle speed at no load and weld speed with load applied.

To Start:

YDo not use ether. Using ether voids warranty.

.If engine does not start, let engine come

to a complete stop before attempting re- start.

Above 325 F (05 C): turn Engine Control switch to Start. Release Engine Control switch when engine starts.

Below 325 F (05 C): push Starting Aid switch up for 60 seconds. While still holding Starting Aid switch, turn Engine Control switch to Start. Release Engine Control switch and Starting Aid switch when engine starts.

To Stop: turn Engine Control switch to Off position.

Engine Gauges And Meters

3 Engine Hour Meter

Use hour meter to monitor engine run time to help schedule maintenance.

4 Fuel Gauge

Use gauge to check fuel level.

To check fuel level when engine is not run- ning, turn Engine Control switch to Run posi- tion

5 Battery Voltmeter (Optional)

Use gauge to check battery voltage and moni- tor the engine charging system. The meter should read about 14 volts dc when the en- gine is running, and about 12 volts dc when the engine is stopped.

6Engine Coolant Temperature Gauge (Optional)

Normal temperature is 180 - 203° F (82 - 95° C). Engine stops if temperature exceeds 220° F (104° C).

7 Engine Oil Pressure Gauge (Optional)

Normal pressure is 30 − 60 psi (207 − 414 kPa). Engine stops if pressure is below 10 psi (69 kPa).

Weld Controls

8 Process/Contactor Switch

See Section 7-3for Process/Contactor switch information.

9 Ampere Range Switch

YDo not switch under load.

Use switch to select weld amperage range.

Use the lowest four ranges for Stick and TIG welding. Read the upper set of numbers at each range for Stick welding and the lower set at each range for TIG welding.

Use the highest range for MIG welding and for cutting and gouging (CAC-A).

For most welding applications, use lowest amperage range possible to help prevent arc outages.

10 Voltage/AmperageAdjust Control

With Process/Contactor switch in any Stick or TIG setting, use control to adjust amperage within range selected by Ampere Range switch. With Process/Contactor switch in any MIG position, use control to adjust voltage. With Voltage/Amperage Adjust Switch in Re- mote position, control limits the remote am- perage in TIG mode, but has no effect in Stick and MIG modes.

Weld output would be about 218 A DC with controls set as shown (50% of 115 to 320 A).

.The numbers around the control are for

reference only and do not represent an actual percentage value.

11Voltage/Amperage Adjust Switch And Remote 14 Receptacle

Use switch to select front panel or remote voltage/amperage control. For remote con- trol, place switch in Remote position and con- nect remote control to Remote 14 receptacle RC14 (see Sections 5-11and 7-4).

12Polarity Switch (Optional)

Y Do not switch under load.

Use Polarity switch to change weld output. Select either DC Electrode Positive (DCEP) or DC Electrode Negative (DCEN).

13Polarity/AC Switch (Optional)

Y Electric shock can kill.

YDo not use AC output in damp areas, if movement is confined, or if there is a danger of falling.

YUse AC output ONLY if required for the welding process. If AC output is re- quired, use remote output control if present on unit.

YDo not switch under load.

Use Polarity/AC switch to select AC or DC weld output and DC weld output polarity. For Direct Current Electrode Negative (DCEN), turn switch to − (Negative) position. For Direct Current Electrode Positive (DCEP), turn switch to + (Positive) position. For weld pro- cesses that require alternating current (AC), use AC position.

Weld Meters

14 AC/DC Voltmeter (Optional)

Voltmeter displays voltage at the weld output terminals, but not necessarily the welding arc due to resistance of cable and connections.

15 AC/DC Ammeter (Optional)

Ammeter displays amperage output of the unit.

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Contents Processes OM-4421215 075NDescription File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting Standards DirectivesDecrot9/06 Decrotsound6/05 Manufacturer European Contact Notified BodyArc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EMPLOI Excessif peut ’AIR Comprimé peut provoquer des blessuresLE Surchauffement peut endom- mager le moteur électrique LES Étincelles Volantes risquent de provoquer des blessuresPour les moteurs à essence LE Soudage À L’ARC risque de provoquer des interférencesPour les moteurs diesel Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone− 50 h Std − DefinitionsStd CC Models CC/CV Models CC Export Models Manufacturer’s Rating LabelsOM-4421 Symbols And Definitions Weld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models MIG Mode Stick ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsExceeding duty cycle can damage unit and void warranty Curve shows typical fuel use under weld or power loadsFuel Consumption Duty Cycle And OverheatingOptional Three-Phase Generator Curves AC Generator Power Curve12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld LoadInstalling Welding Generator − InstallationLocation/Airflow Clearance Grounding1Using Lifting Eye Supporting The Unit Mounting Welding GeneratorMounting Surface To Bolt Unit In PlaceTools Needed 1/2 Installing Exhaust PipeStop engine and let cool Connecting The Battery Activating The Dry Charge Battery If ApplicableDo not overfill battery cells For 30 MinutesEngine Prestart Checks Coolant Recovery TankFull Capacity Engine 9.5 qt 9.01L Diesel Hot Full Cold FullStick and TIG Welding Connecting To Weld Output TerminalsMIG and Fcaw Welding Stop engine150 ft 200 ft 250 ft Selecting Weld Cable Sizes350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Stop engine beforeSocket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsFront Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsDo not switch under load To Start Do not use ether. Using ether voids warrantyEngine Starting Controls Engine Gauges And MetersWeld Control/Arc Condition Information Label Remote Amperage Control On CC Models OptionalExample Combination Remote Amperage Control Stick OM-4421 Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV ModelsVoltage/Amperage Adjust Switch And Remote 14 Receptacle Use switch to select weld amperage range14 AC/DC Voltmeter Optional Process/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsExample Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models OptionalVolt And 240 Volt Receptacles − Operating Auxiliary EquipmentRear Of Panel Single-Phase Generator Power Three-Phase Power ConnectionClose panel opening if no connections are made to generator 240 V 15 a AC South African Receptacle RC1 Optional Generator Power ReceptaclesSupplementary Protector CB2 Supplementary Protector CB3 Maintenance Label − Maintenance & TroubleshootingRoutine Maintenance Checking Generator Brushes By the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hoseStop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Optional Spark Arrestor MufflerTools Needed 3/8 Weld/Power Speed Adjustment Adjusting Engine SpeedEngine Speed No Load Standard Model Idle Speed Ad- justmentServicing Fuel And Lubrication Systems Overload Protection Welding − CC Models TroubleshootingWelding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Only Standard Generator PowerEngine OM-4421 Circuit Diagram For CC Welding Generator − Electrical Diagrams223 522-B Circuit Diagram For CC/CV Welding Generator 223 523-B Wetstacking − RUN-IN ProcedureWelding Generator Procedure at less than Run-In Procedure Using Load BankStop engine Do not touch hot exhaust From flammables Do not PerformBank/grid Run-In Procedure Using Resistance GridFrom flammables Do not perform run-inSelecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible− Parts List 93 −6 105 104 100 101 102 103 Main Assembly 010 Figures 13-2 Figures 13-4 Control Box Assembly − CC Models 087 Control Box Assembly − CC/CV Models -1Item Control Box Assembly − CC/CV ModelsTD1 214 3634 Panel, Front w/Components − CC ModelsPanel, Front w/Components − CC Models -1Item 40 39 Panel, Front w/Components − CC/CV ModelsPanel, Front w/Components − CC/CV Models -1Item 170 Generator -1Item Generator602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Wiring Harnesses PLG4 Harness, receptacle auxiliary power export models includesPage Your distributor also gives ServiceSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s

Big Blue 500 X, Big Blue 400P specifications

Miller Electric has long been a trusted name in the welding industry, and their generators, particularly the Big Blue 400P and Big Blue 500 X, stand out for their performance, reliability, and innovative technologies. These portable diesel welding generators cater to a wide range of applications, from construction sites to industrial fabrication.

The Big Blue 400P is designed for heavy-duty utilization, offering a powerful output of 400 amps at a duty cycle of 60%. It features a dependable Kohler engine that not only provides ample power but also contributes to its efficient fuel consumption, making it an economical choice for extended work sessions. The Big Blue 400P comes equipped with Auto-Stop technology, which automatically turns off the machine when not in use, conserving fuel and extending engine life. This feature showcases Miller's commitment to user-friendly designs that enhance both efficiency and sustainability.

On the other hand, the Big Blue 500 X takes performance up a notch with an impressive 500 amps output and a 60% duty cycle. It is powered by a high-efficiency Yanmar engine that ensures top-notch performance even in the most demanding conditions. This generator is equipped with Miller's X-CASE design, which features a rugged weather-resistant enclosure that protects internal components from harsh environmental conditions, ensuring durability and extended lifespan.

Both machines integrate advanced technologies such as Smart Tech, which optimizes the generator's output based on the specific demands of the welding process. This technology helps maintain a stable arc, enhancing welding quality and consistency. Additionally, both models feature the Auto Remote Start, allowing for quick operations without manual intervention, further advancing ease of use.

The versatility of the Big Blue 400P and 500 X is evident in their ability to perform a variety of welding processes, including Stick, MIG, and TIG. They are equipped with multiple outputs, allowing simultaneous powering of tools and auxiliary equipment, making them indispensable for professionals who need adaptability on the job.

Overall, the Miller Electric Big Blue 400P and 500 X embody the quality, performance, and innovative technologies that Miller Electric is known for. Their robust capabilities, coupled with user-friendly features, make these generators ideal for demanding applications in various industries, ensuring that welders can achieve excellent results, no matter the challenges faced on site.
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