Miller Electric Big Blue 400 PX manual Table of Contents

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TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1.

Symbol Usage

1

1-2.

Arc Welding Hazards

1

1-3.

Engine Hazards

3

1-4.

Compressed Air Hazards

3

1-5. Additional Symbols For Installation, Operation, And Maintenance

4

1-6. California Proposition 65 Warnings

5

1-7.

Principal Safety Standards

5

1-8.

EMF Information

5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

6

2-1.

Signification des symboles

6

2-2. Dangers relatifs au soudage à l’arc

6

2-3. Dangers existant en relation avec le moteur

8

2-4. Dangers liés à l’air comprimé

9

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

9

2-6. Proposition californienne 65 Avertissements

11

2-7. Principales normes de sécurité

11

2-8.

Information EMF

11

SECTION 3 − DEFINITIONS

12

3-1. Warning Label Definitions

12

3-2. Manufacturer’s Rating Label

13

3-3. Symbols And Definitions

14

SECTION 4 − SPECIFICATIONS

15

4-1. Weld And Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4-2. Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4-4.Volt-Ampere Curves − 50 Hz Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4-5.Volt-Ampere Curves − 60 Hz Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-6. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4-7. Duty Cycle And Overheating − 50 Hz Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-8. Duty Cycle And Overheating − 60 Hz Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4-9. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SECTION 5 − INSTALLATION

20

5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 5-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5-6. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5-9. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5-10. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 6-4. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

7-1. 110 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Contents File Engine Drive OM-223 037MProcesses DescriptionFrom Miller to You Table of Contents Warranty Directives StandardsDecrot1/07 Decrotsound200710 Sound Level InformationHOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LE Bruit peut affecter l’ouïe DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LE Soudage peut provoquer un in cendie ou une explosionDES Organes Mobiles peuvent pro voquer des blessures ’EXPLOSION DE LA Batterie peuLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresEn ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMF− Definitions − 50 h StdStd Manufacturer’s Rating Label Symbols And Definitions Dimensions, Weights, And Operating Angles − SpecificationsWeld And Power Specifications Engine SpecificationsVolt-Ampere Curves − 50 Hz Operation Stick ModeMIG Mode TIG ModeDC Amperes Volt-Ampere Curves − 60 Hz Operation100% Duty Cycle At 250 Amperes Curve shows typical fuel use under weld or power loadsFuel Consumption Duty Cycle And Overheating − 50 Hz OperationAC Generator Power Curve Ac power curve shows the gen- erator power in amperesDuty Cycle And Overheating − 60 Hz Operation Grounding1 − InstallationInstalling Welding Generator Location/Airflow ClearanceMounting Welding Generator Installing Exhaust Pipe Stop engine and let coolTools Needed Connecting The Battery Activating The Dry Charge Battery If ApplicableOil Coolant Recovery TankEngine Prestart Checks FuelConnecting To Weld Output Terminals Selecting Weld Cable Sizes Connecting To Remote 14 Receptacle RC14 Gas ConnectionsSocket Information Front Panel Controls See Section StopOM-223 Description Of Front Panel Controls See Section Process/Contactor Switch Settings Process/Contactor SwitchReceptacle RC14 Set Wire ProcessRemote Voltage/Amperage Control Connect RemoteVolt Receptacles − Operating Auxiliary EquipmentRoutine Maintenance − Maintenance & TroubleshootingMaintenance Label Website Address ServicePerkins Customer Assistance Checking Generator BrushesServicing Air Cleaner To clean air filterReinstall primary element and cap dust ejector down Stop engine and let cool Radiator Draincock Inspecting And Cleaning Spark Arrestor MufflerServicing Engine Cooling System Tools Needed 3/8To drain water from fuel system Servicing Fuel And Lubrication SystemsTo change oil and filter To replace primary canister fuel filterOverload Protection Optional Voltmeter/Ammeter Help Displays Help 20 DisplayHelp 25 Display Troubleshooting Standard Generator PowerWelding Engine Sphere oil refineries Coolant temperature is too high see SectionWhen the engine is restarted Engine suddenly stopsCircuit Diagram For Welding Generator − Electrical Diagrams222 966--C − RUN-IN Procedure WetstackingWelding Generator From flammables Run-In Procedure Using Load BankRun-In Procedure Using Resistance Grid − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Amperes x Volts = Watts Farm/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 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible 110− −5 108 109− −3 101 105 104 107 106 102 103 100− −2 − Parts List12−4 5756 112 Dia Part Description Quantity Mkgs Dia Part Description Quantity 213668 Front w/Components PanelPanel Front w/Components Control Panel Generator Rectifier Assembly Wiring Harnesses Material Thickness Gauge Start Your Professional Welding Career Now Support Your distributor also givesYour 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
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