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Miller Electric Big Blue 400 KX Owner's Manual

Engine driven welding generator
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Big Blue 400 KX
OM-4423
September 2005
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
)
File: Engine Drive
215 178N

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Summary of Contents for Miller Electric Big Blue 400 KX

  • Page 1 Big Blue 400 KX Visit our website at www.MillerWelds.com OM-4423 215 178N September 2005 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 TABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance ..............8-2.
  • Page 5 1635 W. Spencer St. Appleton, WI 54914 USA Phone: (920) 734-9821 European Contact Signature: Big Blue 400 KX Declares that the product: conforms to the following Directives and Standards: Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC Arc Welding Equipment −...
  • Page 6 MILLER Europe S.r.l. Via Privata Iseo 6/E 20098 San Giuliano Milanese, Italy Phone: 39(02)98290-1 Fax: 39(02)98290203 Big Blue 400 KX 2000/14/EC, Noise Level of Welding Generators 7/2004 Sound Level Information Measured Sound Power Level: 97 dB Guaranteed Sound Power Level: 98 dB...

  • Page 7: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

  • Page 8: Engine Hazards

    WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.

  • Page 9: Compressed Air Hazards

    STEAM AND HOT COOLANT can burn. D If possible, check coolant level when engine is cold to avoid scalding. D Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). D If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.

  • Page 10: California Proposition 65 Warnings

    READ INSTRUCTIONS. D Use only genuine MILLER/Hobart replacement parts. D Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio naviga- tion, safety services, computers, and communica- tions equipment.

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.

  • Page 12: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- cendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures.

  • Page 13: Dangers Liés À L'air Comprimé

    D Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. D Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. D Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- ver le bouchon.

  • Page 14: Proposition Californienne 65 Avertissements

    LIRE LES INSTRUCTIONS. D Utiliser seulement les pièces de rechange d’origine. D Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences.

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions 0 − 50 h Std. 50 h Std. Notes S-177 571 DIESEL 200A 0 − 200A API CD-MIL L 2104D, CD/SE, CD/SF Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler.

  • Page 16: Manufacturer's Rating Label

    3-2. Manufacturer’s Rating Label 218 449−C OM-4423 Page 10...

  • Page 17: Symbols And Definitions

    3-3. Symbols And Definitions NOTE Some symbols are found only on CE products. Stop Engine Starting Aid (Preheat) Check Injectors/ Pump Positive Amperes Engine Stick (SMAW) Welding Time Three Phase Electrode Connection Duty Cycle Rated Idle Speed Contactor On Fast (Run, Weld/ Power) Battery (Engine) Check Valve...

  • Page 18: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Welding Weld Output Rated Welding Mode Range Output 300 A, 32 Volts DC 20 − 410 A 410 A CC/DC CC/DC 60% Duty Cycle 60% Duty Cycle 250 A, 30 Volts DC 100% Duty cycle 300 A, 29 Volts DC CV/DC...

  • Page 19: Volt-Ampere Curves

    4-3. Volt-Ampere Curves A. Stick Mode DC AMPERES B. MIG Mode DC AMPERES C. TIG Mode DC AMPERES The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown.

  • Page 20: Fuel Consumption

    4-4. Fuel Consumption 2.00 1.75 1.50 1.25 1.00 0.75 0.50 0.25 IDLE 0.00 DC WELD AMPERES AT 100% DUTY CYCLE 4-5. Duty Cycle And Overheating 1000 OM-4423 Page 14 100% Duty Cycle At 250 Amperes Continuous Welding 50 60 % DUTY CYCLE The curve shows typical fuel use under weld or power loads.

  • Page 21: Ac Generator Power Curve

    4-6. AC Generator Power Curve AC AMPERES IN 110V MODE AC AMPERES IN 220V MODE Notes MATERIAL THICKNESS REFERENCE CHART The ac power curve shows the gen- erator power in amperes. 220 346−B 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in)

  • Page 22: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Movement Location Airflow Clearance 18 in (460 mm) 18 in (460 mm) Grounding GND/PE OM-4423 Page 16 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) Electrically bond generator frame to vehicle frame by metal-to-metal contact.

  • Page 23: Mounting Welding Generator

    5-2. Mounting Welding Generator Supporting The Unit Inadequate support. Y Do not use flexible mounts. Using Mounting Brackets Tools Needed: 9/16 in Welding Unit In Place Bolting Unit In Place Y Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion.

  • Page 24: Installing Exhaust Pipe

    5-3. Installing Exhaust Pipe Tools Needed: 1/2 in Notes OM-4423 Page 18 Y Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. 803 582−B / Ref. 217 358-B Work like a Pro! Pros weld and cut safely.

  • Page 25: Activating The Dry Charge Battery (If Applicable)

    5-4. Activating The Dry Charge Battery (If Applicable) 5 A For 30 Minutes 30 A For 12 Minutes Tools Needed: 5-5. Connecting The Battery − Y Always wear a face shield, rubber gloves and protective clothing when working on a battery.

  • Page 26: Engine Prestart Checks

    5-6. Engine Prestart Checks Full Diesel Full Check all engine fluids daily. Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.

  • Page 27: Connecting To Weld Output Terminals

    5-7. Connecting To Weld Output Terminals Y Stop engine. Work (−) Weld Output Terminal CV (Wire) Weld Output Terminal CC (Stick/TIG) Weld Output Terminal Y Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal...

  • Page 28: Selecting Weld Cable Sizes

    5-8. Selecting Weld Cable Sizes* Weld Output Terminals Y Stop engine before Welding connecting to weld out- Amperes put terminals. Y Do not use worn, dam- aged, undersized, or poorly spliced cables. This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable. **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

  • Page 29: Connecting To Remote 14 Receptacle Rc14

    5-9. Connecting To Remote 14 Receptacle RC14 *The remaining sockets are not used. Notes Socket* 24 VOLTS AC 24 VOLTS AC REMOTE OUTPUT OUTPUT CONTROL NEUTRAL Ref 803 576−C Work like a Pro! Pros weld and cut Socket Information 24 volts ac. Protected by circuit breaker CB8.

  • Page 30: Section 6 − Operating Welding Generator

    SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls (See Section 6-2) Stop 217 358-B / 803 576−C OM-4423 Page 24...

  • Page 31: Description Of Front Panel Controls (See Section 6-1)

    6-2. Description Of Front Panel Controls (See Section 6-1) Engine Starting Controls Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). Engine Control Switch Use switch to start engine, select engine speed (if unit has auto idle option), and stop engine.

  • Page 32: Process/Contactor Switch On Cc/Cv Models

    6-3. Process/Contactor Switch On CC/CV Models Switch Setting Switch Setting Remote On/Off Switch Re- GTAW With HF Unit, Pulsing quired −TIG HF Required Or Device, Or Remote Control Scratch Start Remote On/Off Switch Stick (SMAW) With Remote On/Off Required − Stick Remote On/Off Switch MIG (GMAW) Required −...

  • Page 33: Lift-Arce Start Procedure

    6-4. Lift-Arc Start Procedure Lift-Arc Start Method “Touch” Do NOT Strike Like A Match! Notes 1 − 2 Seconds Lift-Arc t TIG With Lift-Arct TIG selected, start arc as follows: TIG Electrode Workpiece Turn gas on. Touch tungsten electrode to workpiece at weld start point.

  • Page 34: Remote Voltage/Amperage Control

    6-5. Remote Voltage/Amperage Control Connect Remote Set TIG or STICK Process Control To Remote Receptacle RC14 Connect Remote Set WIRE Process Control To Remote Receptacle RC14 OM-4423 Page 28 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-9).

  • Page 35: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 110 Volt Receptacles 110/55V 32 A AC Receptalce RC11 110/55V 16A AC Receptacle RC12 Receptacles RC11 and RC12 supply 60 Hz single-phase power at weld/power speed. Maximum output from RC11 is 3.5 kVA/kW. Maximum output from RC12 is 1.8 kVa/kW.

  • Page 36: Section 8 − Maintenance & Troubleshooting

    SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance n = Check Z = Change * To be done by Factory Authorized Service Agent Every FUEL WATER Hours n Fuel/Water Separator n Fuel Level n Coolant Level Every Hours ~ Air Cleaner Element ~ Weld Terminals Every Hours...

  • Page 37: Maintenance Label

    8-2. Maintenance Label OM-4423 Page 31...

  • Page 38: Servicing Air Cleaner

    8-3. Servicing Air Cleaner Keep nozzle 2 in (51 mm) from element. Blow OM-4423 Page 32 Optional Inspect aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 217 358-B Y Stop engine. Y Do not run engine without air cleaner or with dirty element.

  • Page 39: Inspecting And Cleaning Spark Arrestor Muffler

    8-4. Inspecting And Cleaning Spark Arrestor Muffler Tools Needed: 3/8 in 8-5. Servicing Engine Cooling System Y Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole.

  • Page 40: Adjusting Engine Speed On Standard Models

    8-6. Adjusting Engine Speed On Standard Models Engine Speed RPM (Hz) (No Load) 1880 (61.7) Weld/Power Maximum OM-4423 Page 34 Stop Y Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer or frequen- cy meter.

  • Page 41: Servicing Fuel And Lubrication Systems

    8-7. Servicing Fuel And Lubrication Systems Y Stop engine and let cool. Y After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary, and wipe up spilled fuel. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary (Canister) Fuel Filter Secondary (In-Line) Fuel...

  • Page 42: Overload Protection

    8-8. Overload Protection OM-4423 Page 36 Y Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. Fuse F1 F1 protects the stator exciter wind- ing from overload. If F1 opens, weld and generator power is low or stops entirely.

  • Page 43: Checking Generator Brushes

    8-9. Checking Generator Brushes Notes 5/16 in. (8 mm) Minimum Length 9/16 in. (14.3 mm) New Length Replace Damaged Brushes MATERIAL THICKNESS REFERENCE CHART Y Stop engine and let cool. Generator Brush With Spring Mark and disconnect leads at brush hold- er cap.

  • Page 44: Voltmeter/Ammeter Help Displays

    8-10. Voltmeter/Ammeter Help Displays HL.P HL.P HL.P HL.P HL.P HL.P OM-4423 Page 38 Use the Voltmeter/Ammeter help displays to diagnose and correct fault conditions. Indicates a failure of meter display module PC2, or the wiring between PC2 and main control module PC1. If this display is shown, have Facto- ry Authorized Service Agent check PC1, PC2, and the wiring between...

  • Page 45: Troubleshooting

    8-11. Troubleshooting Note Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10). A. Welding Trouble No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote okay at ac receptacles.
  • Page 46 Trouble Check fuse F1, and replace if open (see Section 8-8). Have Factory Authorized Service Agent check vol- tage regulator module PC3. Reset circuit breaker CB3 (see Section 8-8). Check Voltmeter/Ammeter help displays (see Section 8-10). Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit. High output at generator power ac re- Have Factory Authorized Service Agent check voltage regulator module PC3.
  • Page 47 Trouble Battery discharges between uses. Turn Engine Control switch off when unit is not running. Clean top of battery with baking soda and water solution; rinse with clear water. Recharge or replace battery if necessary. Periodically recharge battery (approximately every 3 months). Engine idles, but does not come up to Have Factory Authorized Service Agent check idle module PC5 and current transformer CT1.

  • Page 48: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator OM-4423 Page 42...
  • Page 49 221 499-B OM-4423 Page 43...

  • Page 50: Section 10 − Run-In Procedure

    SECTION 10 − RUN-IN PROCEDURE 10-1. Wetstacking OM-4423 Page 44 run_in1 8/01 Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.
  • Page 51 10-2. Run-In Procedure Using Load Bank Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 52: Run-In Procedure Using Load Bank

    10-3. Run-In Procedure Using Resistance Grid OM-4423 Page 46 Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.
  • Page 53 SECTION 11 − GENERATOR POWER GUIDELINES NOTE The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 11-1. Selecting Equipment 11-2. Grounding Generator To Truck Or Trailer Frame Electrically bond generator frame to vehicle frame by metal-to-metal contact.

  • Page 54: Section 11 − Generator Power Guidelines

    11-3. Grounding When Supplying Building Systems 11-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
  • Page 55 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 11-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 56 11-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
  • Page 57 11-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
  • Page 58 11-10. Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Utility Electrical Service Y Have only qualified persons perform these connections according to all applicable codes and safety practic- Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local...
  • Page 59 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 60: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 3−Fig.12−5 1−Fig.12−3 96−Fig.12−2 OM-4423 Page 54 10 11 Figure 12-1. Main Assembly...
  • Page 61 71−Fig.12−4 803 830−D OM-4423 Page 55...
  • Page 62 Item Dia. Part Mkgs....Figure 12-3 ....217070 ..
  • Page 63 Item Dia. Part Mkgs..... 191626 ....189975 .
  • Page 64 Item Dia. Part Mkgs..... 213600 ....071731 .
  • Page 65 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. Item Dia. Part Mkgs. Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 96 ) ....097926 .
  • Page 66 Item Dia. Part Mkgs. Figure 12-2. Panel, Front w/Components (Continued) ....214543 ....134201 .
  • Page 67 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. Item Dia. Part Mkgs. Figure 12-3. Control Panel (Figure 12-1 Item 1) ....220981 .
  • Page 68 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 17 16 Item Dia. Part Mkgs..ROTOR . . . 212474 ....053390 .
  • Page 69 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. Item Dia. Part Mkgs..... 217081 .
  • Page 70 Note Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness. Item Dia. Part Mkgs..... 217113 .
  • Page 71 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after for your local the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
  • Page 72 File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2005 Miller Electric Mfg. Co. 1/05 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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