Miller Electric Big Blue 400 PX manual RUN-IN Procedure, Wetstacking, Welding Generator

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SECTION 10 − RUN-IN PROCEDURE

10-1. Wetstacking

2

1

run_in1 2007−04

NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur.

1 Welding Generator

Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking. See name- plate, rating label, or specifications section in this manual to find rated voltage and current.

NOTICE − Do not idle engine longer than necessary. Piston rings seat faster if engine runs at weld/power rpm, and the welding generator is kept loaded during run-in.

2 Engine Exhaust Pipe

Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run-in if the engine is run too long at light load or idle rpm.

If exhaust pipe is coated with a wet, black, tar-like substance, dry the engine using one of the following run-in procedures.

See the engine manual for addition- al engine run-in information.

OM-223 037 Page 46

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Contents OM-223 037M ProcessesDescription File Engine DriveFrom Miller to You Table of Contents Warranty Standards DirectivesDecrot1/07 Sound Level Information Decrotsound200710Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer DES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu DES Organes Mobiles peuvent pro voquer des blessures’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicaux− 50 h Std − DefinitionsStd Manufacturer’s Rating Label Symbols And Definitions − Specifications Weld And Power SpecificationsEngine Specifications Dimensions, Weights, And Operating AnglesStick Mode MIG ModeTIG Mode Volt-Ampere Curves − 50 Hz OperationVolt-Ampere Curves − 60 Hz Operation DC AmperesCurve shows typical fuel use under weld or power loads Fuel ConsumptionDuty Cycle And Overheating − 50 Hz Operation 100% Duty Cycle At 250 AmperesAc power curve shows the gen- erator power in amperes AC Generator Power CurveDuty Cycle And Overheating − 60 Hz Operation − Installation Installing Welding GeneratorLocation/Airflow Clearance Grounding1Mounting Welding Generator Stop engine and let cool Installing Exhaust PipeTools Needed Activating The Dry Charge Battery If Applicable Connecting The BatteryCoolant Recovery Tank Engine Prestart ChecksFuel OilConnecting To Weld Output Terminals Selecting Weld Cable Sizes Gas Connections Connecting To Remote 14 Receptacle RC14Socket Information Stop Front Panel Controls See SectionOM-223 Description Of Front Panel Controls See Section Process/Contactor Switch Process/Contactor Switch SettingsSet Wire Process Remote Voltage/Amperage ControlConnect Remote Receptacle RC14− Operating Auxiliary Equipment Volt Receptacles− Maintenance & Troubleshooting Routine MaintenanceMaintenance Label Service Perkins Customer AssistanceChecking Generator Brushes Website AddressTo clean air filter Servicing Air CleanerReinstall primary element and cap dust ejector down Inspecting And Cleaning Spark Arrestor Muffler Servicing Engine Cooling SystemTools Needed 3/8 Stop engine and let cool Radiator DraincockServicing Fuel And Lubrication Systems To change oil and filterTo replace primary canister fuel filter To drain water from fuel systemOverload Protection Help 20 Display Optional Voltmeter/Ammeter Help DisplaysHelp 25 Display Standard Generator Power TroubleshootingWelding Engine Coolant temperature is too high see Section When the engine is restartedEngine suddenly stops Sphere oil refineries− Electrical Diagrams Circuit Diagram For Welding Generator222 966--C Wetstacking − RUN-IN ProcedureWelding Generator Run-In Procedure Using Load Bank From flammablesRun-In Procedure Using Resistance Grid Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsAmperes x Volts = Watts Approximate 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 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Parts List 110− −5 108 109− −3 101 105 104 107 106 102 103 100− −212−4 5756 112 Dia Part Description Quantity Mkgs Dia Part Description Quantity 213668 Panel Front w/ComponentsPanel Front w/Components Control Panel Generator Rectifier Assembly Wiring Harnesses Material Thickness Gauge Start Your Professional Welding Career Now Your distributor also gives SupportTo 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