Miller Electric Big Blue 400P, Big Blue 500 X manual Figures 13-4

Page 75

 

Item

Dia.

Part

Description

Quantity

 

No.

Mkgs.

No.

 

 

 

Figure 13-1. Main Assembly (Continued)

 

 

 

 

 

 

 

. .

120

. . . . . . . . .

. . ♦199 305 . .

TOP, cover front upright ss

. . . 1

. . 121

. . . . . . . . .

. . . 212 944 . .

LABEL, cc stick overlap weld ranges

. . . 1

. .

122

. . . . . . . . .

. . . . . . . . . . . . . .

Not Applicable

. . . .

. . 123

. . . . . . . . .

. . +201 750 . .

UPRIGHT, front

. . . 1

. . 123

. . . . . . . . .

. ♦+202 637 . .

UPRIGHT, front ss

. . . 1

. .

. . . . .

. . . . . . . . .

. . . 223 103 . .

LABEL, ce sound power level 97db (CC export models only)

. . . 1

. .

. . . . .

. . . . . . . . .

. . . 173 216 . .

LABEL, ce european community mark (CC export models only) . . .

. . . 1

. . 124

. . . . . . . . .

. . . 223 379 . .

LABEL, warning general precautionary CSA

. . . 1

. .

125

. . . . . Figures 13-4, 13-5

PANEL, front w/components

. . . 1

. .

126

. . . CT1

. . ♦202 130 . .

XFMR, current sensing

. . . 1

. . 127

. . . . . . . . .

. . +189 828 . .

PANEL, engine side (400P Models)

. . . 1

. . 127

. . . . . . . . .

. ♦+199 301 . .

PANEL, engine side ss

. . . 1

. .

. . . . .

. . . . . . . . .

. . . 190 058 . .

NUT, .250−20 u−nut multi−thread

. . . 19

. .

. . . . .

. . . . . . . . .

. . . 049 525 . .

NUT, 312−18 u−nut multi−thread

. . . 32

. .

. . . . .

. . . . . . . . .

. . . 215 052 . .

KIT, label (includes safety & informational labels) CC models

. . . 1

. .

. . . . .

. . . . . . . . .

. . . 215 212 . .

KIT, label (includes safety & informational labels) CC/CV models . . . .

. . . 1

. .

. . . . .

. . . . . . . . .

. . . 216 989 . .

KIT, label (includes safety & informational labels) (CC export models) . 1

. .

. . . . .

. . . . . . . . .

. . . 216 988 . .

KIT, label (includes safety & informational labels) (CC/CV export models)1

+When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts.

CC CC models only.

CV CC/CV models only. ♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

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Contents File Engine Drive OM-4421215 075NProcesses DescriptionFrom Miller to You Table of Contents − Maintenance & Troubleshooting Directives StandardsDecrot9/06 Decrotsound6/05 Manufacturer European Contact Notified BodyArc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Étincelles Volantes risquent de provoquer des blessures ’AIR Comprimé peut provoquer des blessures’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueBoulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone LE Soudage À L’ARC risque de provoquer des interférencesPour les moteurs à essence Pour les moteurs diesel− Definitions − 50 h StdStd Manufacturer’s Rating Labels CC Models CC/CV Models CC Export ModelsOM-4421 Symbols And Definitions − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models Volt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG ModeDuty Cycle And Overheating Curve shows typical fuel use under weld or power loadsExceeding duty cycle can damage unit and void warranty Fuel Consumption15 kVA/kW Three-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 12 kVA/kW Single-Phase AC Output No Weld LoadGrounding1 − InstallationInstalling Welding Generator Location/Airflow ClearanceUsing Lifting Eye To Bolt Unit In Place Mounting Welding GeneratorSupporting The Unit Mounting SurfaceInstalling Exhaust Pipe Tools Needed 1/2Stop engine and let cool For 30 Minutes Activating The Dry Charge Battery If ApplicableConnecting The Battery Do not overfill battery cellsHot Full Cold Full Coolant Recovery TankEngine Prestart Checks Full Capacity Engine 9.5 qt 9.01L DieselStop engine Connecting To Weld Output TerminalsStick and TIG Welding MIG and Fcaw WeldingStop engine before Selecting Weld Cable Sizes150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mSocket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsFront Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsEngine Gauges And Meters To Start Do not use ether. Using ether voids warrantyDo not switch under load Engine Starting ControlsRemote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Combination Remote Amperage Control Stick OM-4421 Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV ModelsUse switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 Receptacle14 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 EquipmentSingle-Phase Generator Power Three-Phase Power Connection Rear Of PanelClose panel opening if no connections are made to generator Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Supplementary Protector CB2 Supplementary Protector CB3 Maintenance Label − Maintenance & TroubleshootingRoutine Maintenance Checking Generator Brushes Do not clean housing with air hose Servicing Air CleanerBy the warranty To clean air filterInspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. Reinstall cleanout plugTools Needed 3/8 Standard Model Idle Speed Ad- justment Adjusting Engine SpeedWeld/Power Speed Adjustment Engine Speed No LoadServicing 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 − RUN-IN Procedure WetstackingWelding Generator From flammables Do not Perform Run-In Procedure Using Load BankProcedure at less than Stop engine Do not touch hot exhaustDo not perform run-in Run-In Procedure Using Resistance GridBank/grid From flammables− Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical 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 Service Your distributor also givesSupport Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact

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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