Miller Electric Big Blue 500 X, Big Blue 400P manual Welding − CC/CV Models

Page 52

Trouble

Remedy

 

 

No remote fine amperage control.

Repair or replace remote control device.

 

 

 

Have Factory Authorized Service Agent check OCV control circuit.

 

 

B. Welding − CC/CV Models

Trouble

Remedy

 

 

No weld output; generator power output

Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote

okay at ac receptacles.

On/Off Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14

 

(see Sections 5-11and 7-1).

 

 

 

Check position of Ampere Range switch.

 

 

 

Check position of optional Polarity switch or Polarity/AC switch.

 

 

 

Reset supplementary protector CB11 (see Section 9-8).

 

 

 

Reset supplementary protector CB5 (see Section 9-8). Check for faulty remote device connected to

 

RC14.

 

 

 

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).

 

 

 

Have Factory Authorized Service Agent check connector board PC6 and connections.

 

 

 

Check fuse F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check

 

brushes and slip rings, weld excitation circuit, field current regulator board PC1, and the rotor.

 

 

No weld output or generator power out-

Disconnect equipment from generator power receptacles during start-up.

put at ac receptacles.

 

 

 

 

Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent

 

check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

 

 

Erratic weld output.

Check and tighten connections inside and outside unit.

 

 

 

Be sure connection to work piece is clean and tight.

 

 

 

Use dry, properly stored electrodes.

 

 

 

Remove excessive coils from weld cables.

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings.

 

 

High weld output.

Check position of Ampere Range switch and Voltage/Amperage Adjust control.

 

 

 

Check engine speed, and have engine manufacturer’s factory authorized service agent adjust if nec-

 

essary. See Section 9-6for idle speed adjustment.

 

 

 

Have Factory Authorized Service Agent check field current regulator board PC1, and PC1 voltage feed-

 

back circuit.

 

 

Voltage/Amperage control does not

Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere

work when welding in Stick mode.

Range switch in highest range.

 

 

Low weld output.

Check position of Ampere Range switch and Voltage/Amperage Adjust control.

 

 

 

Check engine speed, and have engine manufacturer’s factory authorized service agent adjust if neces-

 

sary. See Section 9-6for idle speed adjustment.

 

 

 

Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent

 

check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

 

 

Electrode sticks to the workpiece more

Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8).

frequently during low voltage (short arc

Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.

length) conditions.

 

 

 

Low open-circuit voltage.

Check engine speed, and have engine manufacturer’s factory authorized service agent adjust if neces-

 

sary. See Section 9-6for idle speed adjustment.

 

 

 

Check position of Process/Contactor switch.

 

 

No remote fine amperage or voltage

Place Voltage/Amperage Adjust switch in Remote position.

control.

 

 

 

 

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).

 

 

OM-4421 Page 46

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Contents OM-4421215 075N ProcessesDescription File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting Standards DirectivesDecrot9/06 Manufacturer European Contact Notified Body Decrotsound6/05Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’AIR Comprimé peut provoquer des blessures ’EMPLOI Excessif peutLE Surchauffement peut endom- mager le moteur électrique LES Étincelles Volantes risquent de provoquer des blessuresLE Soudage À L’ARC risque de provoquer des interférences Pour les moteurs à essencePour 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 Stick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsCurve shows typical fuel use under weld or power loads Exceeding duty cycle can damage unit and void warrantyFuel Consumption Duty Cycle And OverheatingAC Generator Power Curve Optional Three-Phase Generator Curves12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld Load− Installation Installing Welding GeneratorLocation/Airflow Clearance Grounding1Using Lifting Eye Mounting Welding Generator Supporting The UnitMounting Surface To Bolt Unit In PlaceTools Needed 1/2 Installing Exhaust PipeStop engine and let cool Activating The Dry Charge Battery If Applicable Connecting The BatteryDo not overfill battery cells For 30 MinutesCoolant Recovery Tank Engine Prestart ChecksFull Capacity Engine 9.5 qt 9.01L Diesel Hot Full Cold FullConnecting To Weld Output Terminals Stick and TIG WeldingMIG and Fcaw Welding Stop engineSelecting Weld Cable Sizes 150 ft 200 ft 250 ft350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m 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 SectionTo Start Do not use ether. Using ether voids warranty Do not switch under loadEngine 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 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionVoltage/Amperage Adjust Switch And Remote 14 Receptacle Use switch to select weld amperage range14 AC/DC Voltmeter Optional 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 ReceptaclesRear 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 & Troubleshooting Maintenance LabelRoutine Maintenance Checking Generator Brushes Servicing Air Cleaner By the warrantyTo 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 Adjusting Engine Speed Weld/Power Speed AdjustmentEngine Speed No Load 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 Wetstacking − RUN-IN ProcedureWelding Generator Run-In Procedure Using Load Bank Procedure at less thanStop engine Do not touch hot exhaust From flammables Do not PerformRun-In Procedure Using Resistance Grid Bank/gridFrom flammables Do not perform run-inSelecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements 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 Your distributor also gives ServiceSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor 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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