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Miller Electric
Big Blue 400P, Big Blue 500 X manual
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Contents
Main
Big Blue 400P Big Blue 500 X
(Perkins-Powered)
From Miller to You
Page
TABLE OF CONTENTS
Declaration of Conformity for European Community (CE) Products
Manufacturer:European Contact:
Declaration of Conformity for European Community (CE) Products
Manufacturer:European Contact: Notified Body:
OM-4421 Page 1
SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING
Warning: Protect yourself and others from injury read and follow these precautions.
1-1. Symbol Usage
Marks a special safety message.
1-2. Arc Welding Hazards
1-3. Engine Hazards
BATTERY EXPLOSION can BLIND.
FUEL can cause fire or explosion.
MOVING PARTS can cause injury.
HOT PARTS can cause severe burns.
1-4. Compressed Air Hazards
BREATHING COMPRESSED AIR can cause serious injury or death.
COMPRESSED AIR can cause injury.
TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury.
HOT METAL from air arc cutting and gouging can cause fire or explosion.
1-6. California Proposition 65 Warnings
1-7. Principal Safety Standards
1-8. EMF Information
OM-4421 Page 5
SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION
2-1. Signification des symboles
2-2. Dangers relatifs au soudage larc
UN CHOC LECTRIQUE peut tuer.
Une tension DC importante subsiste lintrieur des onduleurs aprs avoir coup lalimentation.
2-3. Dangers existant en relation avec le moteur
LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE.
LE CARBURANT MOTEUR peut provo- quer un incendie ou une explosion.
DES ORGANES MOBILES peuvent pro- voquer des blessures.
DES PIECES CHAUDES peuvent provo- quer des brlures et blessures.
2-4. Dangers lis lair comprim
RESPIRER LAIR COMPRIM peut pro- voquer des blessures graves ou causer la mort.
LAIR COMPRIM peut provoquer des blessures.
LAIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo- quer des blessures.
Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in- cendie ou une explosion.
2-6. Proposition californienne 65 Avertissements
2-7. Principales normes de scurit
2-8. Information EMF
SECTION 3 DEFINITIONS
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3
4
3-1. Warning Label Definitions (For Wordless Labels)
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3-3. Symbols And Definitions
Some symbols are found only on export products.
AAmperes VVolts Panel/Local Remote
3
n
X Duty Cycle U0
SECTION 4 SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Output
Range Rated Welding
Welding Mode Weld Output
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4-4. Volt-Ampere Curves For CC/CV Models
4-5. Fuel Consumption
4-6. Duty Cycle And Overheating
4-7. AC Generator Power Curve
4-8. Optional Three-Phase Generator Curves
SECTION 5 INSTALLATION
5
-1. Installing Welding Generator
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5-3. Mounting Welding Generator
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5-5. Activating The Dry Charge Battery (If Applicable)
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5-6. Connecting The Battery
5-7. Engine Prestart Checks
5-8. Connecting To Weld Output Terminals
5-9. Selecting Weld Cable Sizes*
5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models
5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models
Over 80,000 trained since 1930!
Start Your Professional Welding Career Now!
SECTION 6 OPERATING WELDING GENERATOR CC MODELS
6-1. Front Panel Controls For CC Models (See Section 6-2)
6-2. Description Of Front Panel Controls For CC Models (See Section 6-1)
6-3. Remote Amperage Control On CC Models (Optional)
6-4. Weld Control/Arc Condition Information Label
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SECTION 7 OPERATING WELDING GENERATOR CC/CV MODELS
7-1. Front Panel Controls For CC/CV Models (See Section 7-2)
7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)
7-3. Process/Contactor Switch On CC/CV Models
Process/Contactor Switch Settings
7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)
SECTION 8 OPERATING AUXILIARY EQUIPMENT
8-1. 120 Volt And 240 Volt Receptacles
8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)
8-3. Optional Generator Power Receptacles
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9-2. Routine Maintenance
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9-4. Servicing Air Cleaner
9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler
9-6. Adjusting Engine Speed
9-7. Servicing Fuel And Lubrication Systems
9-8. Overload Protection
9-9. Troubleshooting
A. Welding CC Models
B. Welding CC/CV Models
C. Standard Generator Power
D. Optional Three-Phase Generator Power (CC/CV Models Only)
E. Engine
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SECTION 11 RUN-IN PROCEDURE
11-1. Wetstacking
11-2. Run-In Procedure Using Load Bank
11-3. Run-In Procedure Using Resistance Grid
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SECTION 12 GENERATOR POWER GUIDELINES
12-1. Selecting Equipment
12-2. Grounding Generator To Truck Or Trailer Frame
12-3. Grounding When Supplying Building Systems
12-4. How Much Power Does Equipment Require?
12-5. Approximate Power Requirements For Industrial Motors
12-6. Approximate Power Requirements For Farm/Home Equipment
12-7. Approximate Power Requirements For Contractor Equipment
12-8. Power Required To Start Motor
12-9. How Much Power Can Generator Supply?
12-10. Typical Connections To Supply Standby Power
Pros weld and cut safely. Read the safety rules at the beginning of this manual.
12-11. Selecting Extension Cord (Use Shortest Cord Possible)
SECTION 13 PARTS LIST
Figure 13-1. Main Assembly (Export Model Shown)
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Figure 13-4. Panel, Front w/Components CC Models
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Warranty Questions?
Call 1-800-4-A-MILLER for your local Miller distributor.
Effective January 1, 2007 (Equipment with a serial number preface of LH or newer)
Please complete and retain with your personal records.
For Service
Always provide Model Name and Serial/Style Number.
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Owners Record