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

Page 83

Item

Dia.

 

Part

Description

Quantity

 

No.

 

Mkgs.

 

No.

 

 

 

 

 

Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1Item 125)

 

 

 

 

 

 

 

 

. . .

1

. .

. . . . . . . .

. . .

215 158 . .

PLATE SCREENED, ident control; 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 .

. . .

. 193 118 . .

POT, cp flat 1t 2w 1k ohm linear

. . . 1

. . .

6

. . . . . S6 .

. . .

193 234 . .

SWITCH, rotary 6 position gold contacts

. . . 1

. . .

. . .

. .

. . . . . . . .

. . .

. 197527 . .

Guard, Circuit Breaker (For S6 - Not Included w/Harness)

. . . 1

. . .

7

. . . . . S5 .

. . .

. 011 609 . .

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

. . . 1

. . .

8

. .

. . . . . . . .

. . .

202 209 . .

SPACER, nylon

. . . 2

. . .

9

. . . . PC6 . . .

192 995 . .

CIRCUIT CARD ASSY, connector/receptacle

. . . 1

. 10, 11

CB5, CB6 .

093 995 . .

SUPPLEMENTARY PRO, man reset 1p 15a 250vac frict

. . . 2

. . . 12

. .

. . . S2 .

. . .

021 467 . .

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

. . . 1

. . . 13

. .

. . . S1 .

. . .

212 436 . .

SWITCH, ignition 4posn w/o handle

. . . 1

. . . 14

. .

. . CB1 . . .

201 083 . .

SUPPLEMENTARY PROTECTOR, man reset 2p 20a 250vac

. . . 1

. . .

. . .

. .

. . . . . . . .

. . .

201 553 . .

CLIP, circuit breaker retaining

. . . 1

. . . 15

. .

. . CB2 . . .

093 996 . .

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

. . . 1

. . . 16

. .

. GFCI1 . .

151 981 . .

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

. . . 1

. . . 17

. .

. . RC1 . . .

147 632 . .

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

. . . 1

. . . 17

. .

. . RC1 . . .

176 355 . .

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

. . 1

. . .

. . .

. .

. . CB3 . . .

139 266 . .

SUPPLEMENTARY PROTECTOR, man reset

 

 

 

 

. . RC5 . . ♦182 954

1p 15a 250vac (export models only)

. . . 1

. . . 18

. .

RCPT, str 3P4W 50A 125/250V

. . . 1

. . . 19

. .

. . . . . . . .

. . ♦025 248 . .

STAND-OFF, insul .250-20 x 1.2

. . . 1

. . . 20

. .

. . . . . . . .

. . ♦604 102 . .

CONNECTOR, clamp cable 1.000

. . . 1

. . . 21

. .

. . . . . . . .

. . ♦197 527 . .

GUARD, circuit breaker

. . . 1

. . . 22

. .

. . . . . . . .

. . ♦197 363 . .

TERMINAL, ring tng screw clamp

. . . 3

. . . 23

. .

. . CB7 . . ♦214 926 . .

SUPPLEMENTARY PROTECTOR, man reset 3p 50a 250vac

. . . 1

. . . 24

. .

. . . . . . . .

. .

+215 347 . .

PANEL, generator power

. . . 1

. . . 24

. .

. . . . . . . .

. .

+215 403 . .

PANEL, gen pwr (export models only)

. . . 1

. . . 24

. .

. . . . . . . .

. . ♦215 406 . .

PANEL, generator power ss

. . . 1

. . . 24

. .

. . . . . . . .

. +♦215 363 . .

PANEL, generator power (full kVA option)

. . . 1

. . . 25

. .

. . . . . . . .

. . ♦214 927 . .

BOOT, circuit breaker 1 pole

. . . 1

. . . 26

. .

. . . . . . . .

. . ♦197 508 . .

PLUG, protective

. . . 1

. . . 27

. .

. . . . . . . .

. . ♦077 440 . .

BUSHING, conduit 1 in

. . . 1

. . . 28

. .

. . . . . . . .

. . .

601 836 . .

NUT, 250−20 .50hex .19h brs

. . . 3

. . . 29

. .

. . . . . . . .

. . .

209 056 . .

COVER, receptacle w/gasket

. . . 1

. . . 30

. .

. . . . . . . .

. . .

083 030 . .

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

. . . 1

. . .

. . .

. .

. . CT2

. . ♦197 433 . .

TRANSFORMER, current sensing

. . . 1

. . . 31

. .

. . . . . . . .

. . .

190 861 . .

LABEL, warning electric shock and moving parts etc

. . . 1

. . . 31

. .

. . . . . . . .

. . ♦197 399 . .

LABEL, warning 3 ph generator power

. . . 1

. . . 32

. .

. . . . . . . .

. . .

209 056 . .

COVER, receptacle w/gasket

. . . 2

. . . 33

. .

. . . . . . . .

. . .

206 795 . .

BOOT, circuit breaker clear hex nut

. . . 1

. . . 34

. .

. . . S12

. . ♦195 825 . .

SWITCH, polarity

. . . 1

. . .

. . .

. .

. . . S12

. . ♦220 491 . .

SWITCH, polarity/AC

. . . 1

. . . 35

. .

. . . . . . . .

. . .

201 125 . .

PANEL, mtg terminal pwr output

. . . 1

. . . 35

. .

. . . . . . . .

. . .

199 303 . .

PANEL, mtg terminal pwr output ss

. . . 1

. . . 36

. .

PC4, PC5 .

189 744 . .

CIRCUIT CARD ASSEMBLY, filter hf

. . . 2

. . . 37

. .

. . . . . . . .

. . .

039 046 . .

TERMINAL, pwr output black

. . . 1

. . .

. . .

. .

. . . . . . . .

. . .

180 735 . .

WASHER, output stud

. . . 2

OM-4421 Page 77

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Contents File Engine Drive OM-4421215 075NProcesses DescriptionFrom Miller to You Table of Contents − Maintenance & Troubleshooting Decrot9/06 DirectivesStandards 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 dieselStd − 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 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 SurfaceStop engine and let cool Installing Exhaust PipeTools Needed 1/2 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 ControlsExample Combination Remote Amperage Control Stick Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label OM-4421 Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV Models14 AC/DC Voltmeter Optional Use switch to select weld amperage rangeVoltage/Amperage Adjust Switch And Remote 14 Receptacle 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 EquipmentClose 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 Label − Maintenance & TroubleshootingRoutine Maintenance Checking Generator Brushes Do not clean housing with air hose Servicing Air CleanerBy the warranty To clean air filterTools Needed 3/8 Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug 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 Welding Generator − RUN-IN ProcedureWetstacking 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 flammablesGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment 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 Support ServiceYour distributor also gives 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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