Miller Electric Big Blue 400 KX manual Process/Contactor Switch On CC/CV Models

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6-3. Process/Contactor Switch On CC/CV Models

	1	Process/Contactor Switch
1	Y	Weld output terminals are ener-

gized when Process/Contactor switch is in a Weld Terminals Al- ways On position and the engine is running.

Use switch to select weld process and weld output on/off control (see table be- low).

Place switch in Remote On/Off Switch Required positions to turn weld output on and off with a device connected to the Remote 14 receptacle.

Place switch in Weld Terminals Always On positions for weld output to be on whenever the engine is running.

Use Stick mode for air carbon arc (CAC-A) cutting and gouging.

When switch is in Stick mode, select one of four arc drive (dig) settings to provide additional amperage during low voltage (short arc length) conditions and prevent “sticking” electrodes. Turn control from A to D to increase arc drive (dig) from min to max.

Use the Lift-Arc TIG mode for TIG (GTAW) welding using the Lift-Arc TIG starting procedure (see Section 6-4).

				Ref. 803 576−C / 217 358−B


		Process/Contactor Switch Settings

	Switch Setting	Process	Output On/Off Control	Engine Auto Idle (Optional)

	Remote On/Off Switch Re-	GTAW With HF Unit, Pulsing
	quired −TIG HF Required Or	GTAW With HF Unit, Pulsing	At Remote 14 Receptacle	Active
	quired −TIG HF Required Or	Device, Or Remote Control	At Remote 14 Receptacle	Active
	Scratch Start	Device, Or Remote Control
	Scratch Start

	Remote On/Off Switch	Stick (SMAW) With Remote On/Off	At Remote 14 Receptacle	Active
	Required − Stick	Stick (SMAW) With Remote On/Off	At Remote 14 Receptacle	Active
	Required − Stick

	Remote On/Off Switch	MIG (GMAW)
	Required − CV Feeder	MIG (GMAW)	At Remote 14 Receptacle	Active
	Required − CV Feeder	w/Constant Speed Feeder	At Remote 14 Receptacle	Active
	Using 24 Volt Remote	w/Constant Speed Feeder
	Using 24 Volt Remote

	Weld Terminals Always On −	MIG (GMAW)	Electrode Hot	Active
	Wire	w/Voltage Sensing Feeder	Electrode Hot	Active
	Wire	w/Voltage Sensing Feeder

	Weld Terminals Always On −	Stick (SMAW),
	Weld Terminals Always On −	Air Carbon Arc (CAC-A) Cutting	Electrode Hot	Active
	Stick	Air Carbon Arc (CAC-A) Cutting	Electrode Hot	Active
	Stick	And Gouging
		And Gouging

	Weld Terminals Always On −	TIG Lift-Arc (GTAW)	Electrode Hot	Active
	TIG Lift-Arc	TIG Lift-Arc (GTAW)	Electrode Hot	Active
	TIG Lift-Arc

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Contents OM-4423 215 178N ProcessesDescription File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting 8-1. Routine Maintenance Decrot6/05 DirectivesStandards Sound Level Information Decrotsound1/05Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’AIR Comprimé peut provoquer des blessures ’EMPLOI Excessif peutLE Surchauffement peut endom- mager le moteur électrique LES Étincelles Volantes risquent de provoquer des blessuresLE Soudage À L’ARC risque de provoquer des interférences Pour les moteurs à essencePour les moteurs diesel Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphoneStd − Definitions− 50 h Std Manufacturer’s Rating Label Symbols And Definitions Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Stick Mode MIG ModeTIG Mode Volt-Ampere CurvesCurve shows typical fuel use under weld or power loads Exceeding duty cycle can damage unit and void warrantyFuel Consumption Duty Cycle And OverheatingAC Generator Power Curve Ac power curve shows the gen- erator power in amperes− Installation Installing Welding GeneratorMounting Welding Generator Stop engine and let cool Installing Exhaust PipeTools Needed 1/2 Activating The Dry Charge Battery If Applicable Connecting The BatteryDo not overfill battery cells Connect Negative − Cable LastCoolant Recovery Tank Engine Prestart ChecksFuel Do not use gasoline. Gasoline will damage engine OilConnecting To Weld Output Terminals Stick and TIG WeldingMIG and Fcaw Welding Stop engineSelecting Weld Cable Sizes 150 ft 200 ft 250 ft350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Stop engine beforeConnecting To Remote 14 Receptacle RC14 SocketFront Panel Controls See Section StopDescription Of Front Panel Controls See Section Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsLift-ArcStart Procedure Lift-Arc Start Method TouchDo not Strike Like a Match Lift-Arc t TIGRemote Voltage/Amperage Control − Operating Auxiliary Equipment Volt Receptacles− Maintenance & Troubleshooting Routine MaintenanceMaintenance Label Servicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hoseServicing Engine Cooling System Inspecting And Cleaning Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug Adjusting Engine Speed On Standard Models MaximumServicing Fuel And Lubrication Systems Stop engine and let cool After servicing, start engineTo change oil and filter To replace primary canister fuel filterPress button to reset breaker Overload ProtectionChecking Generator Brushes Replace Damaged BrushesHelp 25 Display Voltmeter/Ammeter Help DisplaysHelp 20 Display Welding TroubleshootingStandard Generator Power Engine Check for obstructed throttle solenoid − Electrical Diagrams Circuit Diagram For Welding Generator221 499-B Welding Generator − RUN-IN ProcedureWetstacking Run-In Procedure Using Load Bank Procedure at less thanStop engine Do not touch hot exhaust From flammables Do not PerformRun-In Procedure Using Resistance Grid Bank/gridFrom flammables Do not perform run-inGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Amperes x Volts = WattsApproximate 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 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 103 − −5 104 − −3 96− −2 102 101 10071− −4 3031 5756Dia Part Description Quantity Mkgs Dia Part Description Quantity 213600 Panel, Front w/Components Panel, Front w/Components -1ItemFUEL/HM Control Panel Generator Generator -1ItemRectifier Assembly Wiring Harnesses Support ServiceYour distributor also gives To 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