Miller Electric Big Blue 400P, Big Blue 500 X manual Panel, Front w/Components − CC Models -1Item

Page 81

Item

Dia.

Part

Description

Quantity

No.

Mkgs.

No.

Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1Item 125)

. . .

1

. . . . . . . . . .

. . .

215 070 . .

PLATE SCREENED, ident control rating; when ordering this item,

 

. . . .

. .

. . . . . . . . . .

. . .

. . . . . . . . . . .

the nameplate should also be ordered)

. . 1

. . .

2

. . . . . . . . . .

. . .

. . . . . . . . . . .

NAMEPLATE, screened (order by model and serial number)

. . 1

. . .

3

. . . . . . . . . .

. . .

215 014 . .

PANEL, engine/weld control

. . 1

. . .

3

. . . . . . . . . .

. . ♦220 544 . .

PANEL, engine/weld control ss

. . 1

. . .

4

. . . . . S3 .

. . .

208 278 . .

SWITCH, range/changeover

. . 1

. . . 5

. . . . . R1 .

. . .

188 635 . .

RHEOSTAT, WW 300W 34 ohm

. . 1

. . .

6

. . . . . . . . . .

. . .

202 209 . .

SPACER, nylon

. . 3

. . .

7

. . . . . S6 .

. . .

. 011 622 . .

SWITCH, tgl DPDT 15A 125VAC

. . 1

. . .

8

. . . . . S5 .

. . .

. 011 609 . .

SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr

. . 1

. . . 9

. . . . RC13

. . .

032 897 . .

RECEPTACLE, twlk grd 2P3W 15A 125V

. . 1

. . . 10

. . . . . S1 .

. . .

212 436 . .

SWITCH, ignition 4 position w/handle

. . 1

. . . 11

. . . . . S2 .

. . .

021 467 . .

SWITCH, tgl spst 3a 250v off−none−(on) spd term

. . 1

. . . .

. .

. . . . . . . . . .

. . .

201 553 . .

CLIP, circuit breaker retaining

. . 1

. . . 12

. . . . CB1 . . .

201 083 . .

SUPPLEMENTARY PROTECTOR, man reset 2p 20a 250vac

. . 1

. . . 13

. . . . CB2 . . .

093 996 . .

SUPPLEMENTARY PRO, man reset 1p 20a 250vac frict

. . 1

. . . 14

. . . GFCI1 . .

151 981 . .

RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI

. . 1

. . . 15

. . . . RC1 . . .

147 632 . .

RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R

. . 1

. . . 15

. . . . RC1 . . .

176 355 . .

RECEPTACLE, str 2p3w 16a 220v flange mtg (export models only)

. . 1

. . . .

. .

. . . . CB3 . . .

139 266 . .

SUPPLEMENTARY PROTECTOR, man reset

 

 

 

 

 

 

1p 15a 250vac (export models only)

. . 1

. . . 16

. . . . . . . . . .

. . .

190 861 . .

LABEL, warning electric shock and moving parts etc

. . 1

. . . 17

. . . . . . . . . .

. .

+215 347 . .

PANEL, gen pwr

. . 1

. . . 17

. . . . . . . . . .

. ♦+215 405 . .

PANEL, gen pwr ss

. . 1

. . . 17

. . . . . . . . . .

. ♦+215 403 . .

PANEL, gen pwr (export models only)

. . 1

. . . 18

. . . . . . . . . .

. . .

083 030 . .

STUD, brs .250−20 x 1.750 w/hex collar

. . 1

. . . 19

. . . . . . . . . .

. . .

601 836 . .

NUT, 250−20 .50hex .19h brs

. . 3

. . . 20

. . . . . . . . . .

. . ♦196 073 . .

LABEL, do not switch while welding

. . 1

. . . 21

. . . . . S12

. . ♦195 825 . .

SWITCH, polarity

. . 1

. . . 21

. . . . . S12

. . ♦220 491 . .

SWITCH, polarity/ac

. . 1

. . . 22

. . . . . . . . . .

. . .

201 125 . .

PANEL, mtg terminal pwr output

. . 1

. . . 22

. . . . . . . . . .

. . ♦199 303 . .

PANEL, mtg terminal pwr output ss

. . 1

. . . 23

. . . . . . . . . .

. . .

039 046 . .

TERMINAL, pwr output black

. . 1

. . . .

. .

. . . . . . . . . .

. . .

180 735 . .

WASHER, output stud

. . 2

. . . 24

. . . . . . . . . .

. . .

181 169 . .

SPACER, output stud

. . 2

. . . 25

. . . . . . . . . .

. . .

186 621 . .

BOOT, generic output stud

. . 2

. . . 26

. . . . . . . . . .

. . ♦059 773 . .

HANDLE, switch

. . 1

. . . 27

. . . . . . . . . .

. . ♦010 647 . .

PIN, spring cs .156 x 1.250

. . 1

. . . 28

. . . . . . . . . .

. . .

039 047 . .

TERMINAL, pwr output red

. . 1

. . . 29

. . . . . . . . . .

. . .

209 056 . .

COVER, receptacle w/gasket

. . 2

. . . 30

. . . . . . . . . .

. . .

206 795 . .

BOOT, circuit breaker clear hex nut

. . 1

. . . 31

. . . . . . . . . .

. . .

021 385 . .

BOOT, toggle switch lever

. . 2

. . . 32

. . . . . . . . . .

. . .

201 045 . .

COVER, receptacle twistlock

. . 1

. . . 33

. . . . . . . . . .

. . ♦193 228 . .

METER, Volt Dc 8− 18 Scale 2.250 In Black Face

. . 1

. . . 34

. . . . FUEL

. . .

192 265 . .

GAUGE, fuel elec switch w/o sensor

. . 1

. . . 35

. . . . . HM .

. . .

210 424 . .

METER, hour 12-24VDC 2.25dia

. . 1

. . . 36

. . . . . . . . . .

. . .

217 084 . .

GAUGE, Coolant Temp 0− 300 Deg F Electric

. . 1

OM-4421 Page 75

Page 80 Page 82
Image 81
Page 80 Page 82
Contents Processes OM-4421215 075NDescription File Engine DriveFrom 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 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− 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 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 PlaceInstalling Exhaust Pipe Tools Needed 1/2Stop 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 MetersRemote 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 By the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hoseInspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. Reinstall cleanout plugTools 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 − RUN-IN Procedure WetstackingWelding 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-in− Generator Power Guidelines Selecting EquipmentGrounding 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 Service Your distributor also givesSupport 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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