Miller Electric Big Blue 500 X, Big Blue 400P manual Overload Protection

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9-8. Overload Protection

2

9

8

7

4 5

1

YStop engine.

.When a supplementary protector,

circuit breaker or fuse opens, it usu- ally indicates a more serious problem exists. Contact Factory Authorized Service Agent.

1Fuse F1

2Fuse F2

F1 and F2 protect the stator exciter wind- ing from overload. If F1 opens, weld and generator power is low or stops entirely. If F2 opens, weld output is low or stops entirely. 4 kVA/kW generator power is still available.

3Circuit Breaker CB4 (Not Shown)

4Supplementary Protector CB5 (CC/CV Models Only)

5Supplementary Protector CB6 (CC/CV Models Only)

6Circuit Breaker CB10 (Not Shown)

7Supplementary Protector CB11

8Supplementary Protector CB12

9Supplementary Protector CB13

10Circuit Breaker CB14 (Not Shown)

CB4 protects the welding arc drive (dig) circuit. If CB4 opens, electrode may stick to the workpiece more frequently during low voltage (short arc length) conditions. CB4 automatically resets when the fault is corrected.

CB5 protects the 24 volt ac output to re- mote receptacle RC14, and 24 volt output to field current regulator board PC1 (CC/ CV models only). If CB5 opens, weld out- put and 24 volt output to RC14 stops. On units with optional three-phase genera- tor, generator power output at receptacle RC5 also stops if CB5 opens.

CB6 protects the 115 volt ac output to re- mote receptacle RC14 (CC/CV models only). If CB6 opens, 115 volt output to RC14 stops.

CB10 protects the engine battery circuit. If CB10 opens, the engine will not crank. CB10 automatically resets when the fault is corrected.

CB11 protects the weld control circuit. On

CCmodels, if CB11 opens the max OCV circuit does not work and open circuit voltage is variable at all times (see max OCV note under Weld Controls in Section 6-2). If CB11 opens on CV models, weld output stops (generator power is still available).

CB12 protects the field flashing circuit. If CB12 opens, the generator may not ex- cite at start-up and weld and generator power output may not be available.

CB13 protects the engine control circuit. If CB13 opens, the engine does not crank.

CB14 protects throttle solenoid TS1 on units with auto idle option. If CB14 opens, the engine does not run at idle speed. CB14 automatically resets when the fault is corrected.

Press button to reset supplementary pro- tector.

803 605

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Contents Description OM-4421215 075NProcesses File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting Decrot9/06 DirectivesStandards Manufacturer European Contact Notified Body Decrotsound6/05Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLE Surchauffement peut endom- mager le moteur électrique ’AIR Comprimé peut provoquer des blessures’EMPLOI Excessif peut LES Étincelles Volantes risquent de provoquer des blessuresPour les moteurs diesel LE Soudage À L’ARC risque de provoquer des interférencesPour les moteurs à essence Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphoneStd − Definitions− 50 h Std OM-4421 Manufacturer’s Rating LabelsCC Models CC/CV Models CC Export Models Symbols And Definitions Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Volt-Ampere Curves For CC Models TIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Curve shows typical fuel use under weld or power loadsExceeding duty cycle can damage unit and void warranty Duty Cycle And Overheating12 kVA/kW Single-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 15 kVA/kW Three-Phase AC Output No Weld LoadLocation/Airflow Clearance − InstallationInstalling Welding Generator Grounding1Using Lifting Eye Mounting Surface Mounting Welding GeneratorSupporting The Unit To Bolt Unit In PlaceStop engine and let cool Installing Exhaust PipeTools Needed 1/2 Do not overfill battery cells Activating The Dry Charge Battery If ApplicableConnecting The Battery For 30 MinutesFull Capacity Engine 9.5 qt 9.01L Diesel Coolant Recovery TankEngine Prestart Checks Hot Full Cold FullMIG and Fcaw Welding Connecting To Weld Output TerminalsStick and TIG Welding Stop engine350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Selecting Weld Cable Sizes150 ft 200 ft 250 ft Stop engine beforeConnecting To Remote 14 Receptacle RC14 On CC/CV Models Socket− Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionEngine Starting Controls To Start Do not use ether. Using ether voids warrantyDo not switch under load Engine Gauges And MetersExample Combination Remote Amperage Control Stick Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label OM-4421 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See Section14 AC/DC Voltmeter Optional Use switch to select weld amperage rangeVoltage/Amperage Adjust Switch And Remote 14 Receptacle Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIG− Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesClose panel opening if no connections are made to generator Single-Phase Generator Power Three-Phase Power ConnectionRear Of Panel Supplementary Protector CB2 Supplementary Protector CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 − Maintenance & Troubleshooting Maintenance LabelRoutine Maintenance Checking Generator Brushes To clean air filter Servicing Air CleanerBy the warranty Do not clean housing with air hoseTools Needed 3/8 Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug Engine Speed No Load Adjusting Engine SpeedWeld/Power Speed Adjustment Standard Model Idle Speed Ad- justmentServicing Fuel And Lubrication Systems Overload Protection Troubleshooting Welding − CC ModelsWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine OM-4421 − Electrical Diagrams Circuit Diagram For CC Welding Generator223 522-B Circuit Diagram For CC/CV Welding Generator 223 523-B Welding Generator − RUN-IN ProcedureWetstacking Stop engine Do not touch hot exhaust Run-In Procedure Using Load BankProcedure at less than From flammables Do not PerformFrom flammables Run-In Procedure Using Resistance GridBank/grid Do not perform run-inGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Earth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− 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 Control Box Assembly − CC/CV Models -1ItemTD1 214 Panel, Front w/Components − CC Models 3634Panel, Front w/Components − CC Models -1Item Panel, Front w/Components − CC/CV Models 40 39Panel, Front w/Components − CC/CV Models -1Item 170 Generator Generator -1Item602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Wiring Harnesses Harness, receptacle auxiliary power export models includes PLG4Page Support ServiceYour distributor also gives For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co 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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