Miller Electric Big Blue 400 KX manual Description Of Front Panel Controls See Section

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

Engine Starting Controls

1 Preheat Switch

Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing).

2 Engine Control Switch

Use switch to start engine, select engine speed (if unit has auto idle option), and stop engine.

In Run position, engine runs at weld/power speed. In Auto position (optional), engine runs at idle speed at no load and weld speed with load applied.

3 Engine Stop Lever

Use lever to stop engine if Engine Control switch does not work.

.The Engine Stop lever shuts off the fuel

supply. However, the Engine Stop lever will not stop the engine if the engine can draw fuel-rich air from the surrounding atmosphere (oil refineries).

To Start:

YDo not use ether.

.If engine does not start, let engine come

to a complete stop before attempting re- start.

Above 325 F (05 C): turn Engine Control switch to Start. Release Engine Control switch when engine starts.

Below 325 F (05 C): turn engine control switch to Auto position. Push Preheat switch up for 60 seconds. Turn Engine Control switch to Start. Release Engine Control switch and Preheat switch when engine starts.

To Stop: turn Engine Control switch to Off position.

Engine Gauges, Meters, And Lights

4 Fuel Gauge/Hourmeter

Use gauge to check fuel level or total engine operating hours.

To check fuel level or engine hours when en- gine is not running, turn Engine Control switch to Run or Auto (optional) position.

5 Engine Indicator Light

Light goes on and engine stops if engine tem- perature exceeds 230° F (110° C) or engine oil pressure is below 10 psi (69 kPa).

.Normal engine temperature is 180 - 2035 F (82 - 955 C). Normal oil pressure is 30

-60 psi (207 - 414 kPa).

YDo not run engine until trouble is fixed.

Weld Controls

6 Remote Control Receptacle

Use receptacle to connect remote controls, wire feeders, and tools.

When a remote control is connected to the Remote receptacle, the Auto Sense Remote feature automatically switches voltage/am- perage control to the remote control (see Sec- tion 5-9).

With remote control connected, weld output is determined by a combination of front panel and remote control voltage/amperage set- tings.

If no remote control is connected to the Re- mote receptacle, the front panel Voltage/Am- perage control adjusts voltage and amper- age.

.If a remote device connected to Remote

Receptacle RC14 is faulty or is discon- nected, the meters display Help 25 (see Section 8-10). Clear fault by stopping and restarting the unit or by turning Pro- cess/Contactor switch to another posi- tion.

7 Process/Contactor Switch

See Section 6-3for Process/Contactor switch information.

8 Voltage/Amperage Control

With Process/Contactor switch in any Stick or TIG setting, use control to adjust amperage. With Process/Contactor switch in any Wire (MIG) position, use control to adjust voltage. With Voltage/Amperage Adjust Switch in Re- mote position, control limits the remote am- perage in Stick or TIG mode, but has no effect in Wire (MIG) modes.

Weld Meters

.Weld meters also work in combination to

display troubleshooting help codes (see Section 8-10).

9 DC Voltmeter

Voltmeter displays preset voltage (MIG weld- ing) with contactor off, and actual output volt- age with the contactor on. Voltmeter displays voltage at the weld output terminals, but not necessarily the welding arc due to resistance of cable and connections.

To set voltage, turn contactor off and turn Pro- cess/Contactor switch to Wire position. Turn V/A control until desired voltage is displayed on Voltmeter. When welding is finished, volt- meter displays weld voltage and then defaults to preset voltage.

10 DC Ammeter

Ammeter displays preset amperage (Stick and TIG only) when not welding, and actual output amperage when welding.

To set amperage, turn Process/Contactor switch to Stick or TIG position. Turn V/A con- trol until desired amperage is displayed on Ammeter. When welding is finished, ammeter displays weld amperage and then defaults to preset amperage.

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Contents File Engine Drive OM-4423 215 178NProcesses DescriptionFrom Miller to You Table of Contents − Maintenance & Troubleshooting 8-1. Routine Maintenance Standards DirectivesDecrot6/05 Decrotsound1/05 Sound Level InformationArc 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− 50 h Std − DefinitionsStd Manufacturer’s Rating Label Symbols And Definitions Weld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves 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 ConsumptionAc power curve shows the gen- erator power in amperes AC Generator Power CurveInstalling Welding Generator − InstallationMounting Welding Generator Tools Needed 1/2 Installing Exhaust PipeStop engine and let cool Connect Negative − Cable Last Activating The Dry Charge Battery If ApplicableConnecting The Battery Do not overfill battery cellsOil Coolant Recovery TankEngine Prestart Checks Fuel Do not use gasoline. Gasoline will damage engineStop 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 RC14Stop Front Panel Controls See SectionDescription Of Front Panel Controls See Section Process/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsLift-Arc t TIG Lift-ArcStart ProcedureLift-Arc Start Method Touch Do not Strike Like a MatchRemote Voltage/Amperage Control Volt Receptacles − Operating Auxiliary EquipmentRoutine Maintenance − Maintenance & TroubleshootingMaintenance Label Do not clean housing with air hose Servicing Air CleanerBy the warranty To clean air filterStop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Spark Arrestor MufflerServicing Engine Cooling System Maximum Adjusting Engine Speed On Standard ModelsTo replace primary canister fuel filter Servicing Fuel And Lubrication SystemsStop engine and let cool After servicing, start engine To change oil and filterOverload Protection Press button to reset breakerReplace Damaged Brushes Checking Generator BrushesHelp 20 Display Voltmeter/Ammeter Help DisplaysHelp 25 Display Standard Generator Power TroubleshootingWelding Engine Check for obstructed throttle solenoid Circuit Diagram For Welding Generator − Electrical Diagrams221 499-B Wetstacking − RUN-IN ProcedureWelding 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 flammablesSelecting Equipment − Generator Power GuidelinesGrounding 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 Possible103 − −5 104 − −3 96− −2 102 101 100 − Parts List3031 5756 71− −4Dia Part Description Quantity Mkgs Dia Part Description Quantity 213600 Panel, Front w/Components -1Item Panel, Front w/ComponentsFUEL/HM Control Panel Generator -1Item GeneratorRectifier Assembly Wiring Harnesses Your distributor also gives ServiceSupport 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
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