Miller Electric Big Blue 400 PX Owner's Manual
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Miller Electric Big Blue 400 PX Owner's Manual

Miller Electric Big Blue 400 PX Owner's Manual

Engine driven welding generator
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Big Blue 400 PX
Processes
Description
Engine Driven Welding Generator
)
(50/60 Hz)
OM-223 037M
2007−11
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
File: Engine Drive

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Summary of Contents for Miller Electric Big Blue 400 PX

  • Page 1 Big Blue 400 PX Visit our website at www.MillerWelds.com OM-223 037M 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 (50/60 Hz) File: Engine Drive...
  • 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 PX Declares that the product: conforms to the following Directives and Standards: Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC, 2004/108/EC Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC Arc Welding Equipment −...
  • Page 6 ITW Welding Products Italy 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 PX 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 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 8 FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.

  • Page 9: Engine Hazards

    1-3. Engine Hazards BATTERY EXPLOSION can BLIND. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Stop engine before disconnecting or connect- ing battery cables or servicing battery. D Do not allow tools to cause sparks when working on a battery. D Do not use welder to charge batteries or jump start vehicles.

  • Page 10: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and gouging can cause fire or explosion. D Do not cut or gouge near flammables. D Watch for fire; keep extinguisher nearby. HOT PARTS can cause burns and injury. D Do not touch hot compressor or air system parts.

  • Page 11: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

  • Page 12: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
  • Page 13 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. D Ne pas toucher à mains nues les parties chau- des. D Prévoir une période de refroidissement avant de travailler à l’équipement. D Ne pas toucher aux pièces chaudes, utiliser les outils recomman- dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.

  • Page 14: Dangers Existant En Relation Avec Le Moteur

    LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux. D Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance. D Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de sou- dage par points, de gougeage, du coupage plasma ou de chauf- fage par induction.

  • Page 15: Dangers Liés À L'air Comprimé

    L’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. D Les fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore. D JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes. D Uniquement utiliser à...
  • Page 16 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. D Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur. D Ne pas laisser tourner le moteur trop lentement sous risque d’en- dommager le moteur électrique à cause d’une tension et d’une fré- quence trop faibles.

  • Page 17: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé...

  • Page 18: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions 0 − 50 h Std. 50 h Std. Notes OM-223 037 Page 12 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.

  • Page 19: Manufacturer's Rating Label

    3-2. Manufacturer’s Rating Label 223 081-A / Ref 804 068-E OM-223 037 Page 13...

  • Page 20: Symbols And Definitions

    3-3. Symbols And Definitions 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 Emergency Stop OM-223 037 Page 14 Fast (Run, Weld/ Power)

  • Page 21: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld And Power Specifications Weld Output Weld Output Welding Range At Range At Mode 60 Hz 50 Hz (1800 rpm) (1500 rpm) 20 − 410 A 410 A 20 − 300 A 300 A CC/DC CC/DC CV/DC 14 −...

  • Page 22: Volt-Ampere Curves − 50 Hz Operation

    4-4. Volt-Ampere Curves − 50 Hz Operation A. Stick Mode B. MIG Mode MA X C. TIG Mode OM-223 037 Page 16 2 0 0 30 0 2 00 DC AMPERES DC AMPERES DC AMPERES The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator.

  • Page 23: Volt-Ampere Curves − 60 Hz Operation

    4-5. Volt-Ampere Curves − 60 Hz Operation A. Stick Mode B. MIG Mode C. TIG Mode 2 00 DC AM PERES DC AM PERES DC AMPERES The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator.

  • Page 24: Fuel Consumption

    4-6. Fuel Consumption 2.00 1.75 1.50 1.25 1.00 0.75 0.50 ID LE 0.25 0.00 DC WELD AMPERES AT 100% DUTY CYCLE − 60 HZ 4-7. Duty Cycle And Overheating − 50 Hz Operation OM-223 037 Page 18 The curve shows typical fuel use under weld or power loads.

  • Page 25: Duty Cycle And Overheating − 60 Hz Operation

    4-8. Duty Cycle And Overheating − 60 Hz Operation 1000 4-9. AC Generator Power Curve 2 40 2 00 1 60 1 20 50 60 % DUTY CYCLE AC AMPERES IN 110 V MODE A C A MPERES IN 22 0V MODE 100% Duty Cycle At 250 Amperes Continuous Welding Duty Cycle is percentage of 10 min-...

  • Page 26: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Movement Location/Airflow Clearance 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) (460 mm) Grounding GND/PE OM-223 037 Page 20 18 in (460 mm) 18 in Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica-...

  • Page 27: Mounting Welding Generator

    5-2. Mounting Welding Generator Supporting The Unit Inadequate support. Do not use flexible mounts. Using Mounting Brackets Tools Needed: 9/16 in Welding Unit In Place Bolting Unit In Place install3 2007−04 803 274 / 200 864-A / 804 068-E Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion.

  • Page 28: Installing Exhaust Pipe

    5-3. Installing Exhaust Pipe Tools Needed: 1/2 in Notes OM-223 037 Page 22 Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. 803 582−G / Ref. 222 875-A Work like a Pro! Pros weld and cut safely.

  • Page 29: 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 Tools Needed: 1/2 in − Always wear a face shield, rubber gloves and protective clothing when working on a battery.

  • Page 30: Engine Prestart Checks

    5-6. Engine Prestart Checks Full Diesel Check all engine fluids daily. The engine will not run if engine access door is open or Emergency Stop switch has been pressed (see Section 6-1). Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil.

  • Page 31: Connecting To Weld Output Terminals

    5-7. Connecting To Weld Output Terminals Stop engine. Work (−) Weld Output Terminal CV (Wire) Weld Output Terminal CC (Stick/TIG) Weld Output Terminal Making Connections Weld Output Terminal Supplied Weld Output Terminal Weld Cable Terminal Copper Bar Remove supplied nut from weld out- put terminal.

  • Page 32: Selecting Weld Cable Sizes

    5-8. Selecting Weld Cable Sizes* Weld Output Terminals Stop engine before Welding connecting to weld Amperes output terminals. 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) based on a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

  • Page 33: Connecting To Remote 14 Receptacle Rc14

    5-9. Connecting To Remote 14 Receptacle RC14 * The remaining sockets are not used. 5-10. Gas Connections Socket* 24 VOLTS AC 24 VOLTS AC REMOTE OUTPUT OUTPUT CONTROL NEUTRAL Ref 804 068 Tools Needed: 5/8, 1-1/8 in Socket Information 24 volts ac. Protected by sup- plementary protector CB8.

  • Page 34: Section 6 − Operating Welding Generator

    SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls (See Section 6-2) Stop 218 379−A / Ref 804 068 / 804 009−A OM-223 037 Page 28...

  • Page 35: Description Of Front Panel Controls (See Section 6-1)

    6-2. Description Of Front Panel Controls (See Section 6-1) Engine Controls The engine will not run if engine access door is open or Emergency Stop switch has been pressed. Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing).

  • Page 36: Process/Contactor Switch

    6-3. Process/Contactor Switch Switch Setting Switch Setting GTAW With HF Unit, Pulsing Device, Or Remote Remote On/Off Switch Required −TIG Remote On/Off Switch Required − Stick Remote On/Off Switch Required − CV Feeder Using Remote Weld Terminals Always On − Wire Weld Terminals Always On −...

  • Page 37: Remote Voltage/Amperage Control

    6-4. Remote Voltage/Amperage Control In Example: Min = 20 A DC Max = 205 A DC Connect Remote Control To Remote Receptacle RC14 Set TIG or STICK Process Connect Remote Control To Remote Receptacle RC14 Set WIRE Process Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-9).

  • Page 38: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 110 Volt Receptacles 110 V 32 A AC Receptacle RC11 110 V 16A AC Receptacle RC12 110 V 16 A AC Receptacle RC13 Receptacles supply 50 Hz single-phase power with Engine Speed switch in 50 Hz/20-300A (1500 rpm) position (see Sec- tion 6-1).

  • Page 39: Section 8 − Maintenance & Troubleshooting

    SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance The engine will not run if engine access door is open or Emergency Stop switch has been pressed (see Section 6-1). n = Check Z = Change * To be done by Factory Authorized Service Agent Every Hours n Coolant Level...

  • Page 40: Maintenance Label

    8-2. Maintenance Label OM-223 037 Page 34...

  • Page 41: Perkins Customer Assistance

    8-3. Perkins Customer Assistance Service When a problem arises concerning the op- eration or service of the engine, the prob- lem will normally be managed by the dealer in your area. Your satisfaction is a primary concern to Perkins and to Perkins dealers. If you have 8-4.

  • Page 42: Servicing Air Cleaner

    8-5. Servicing Air Cleaner Keep nozzle 2 in (51 mm) from element. Blow OM-223 037 Page 36 Optional Inspect aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 214 778-B Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element.

  • Page 43: Inspecting And Cleaning Spark Arrestor Muffler

    8-6. Inspecting And Cleaning Spark Arrestor Muffler 8-7. Servicing Engine Cooling System 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 44: Servicing Fuel And Lubrication Systems

    8-8. Servicing Fuel And Lubrication Systems Tools Needed: OM-223 037 Page 38 Stop engine and let cool. 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...

  • Page 45: Overload Protection

    8-9. Overload Protection Stop engine. When a supplementary protec- tor, circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory 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 46: Optional Voltmeter/Ammeter Help Displays

    8-10. Optional Voltmeter/Ammeter Help Displays HL.P HL.P HL.P HL.P HL.P HL.P OM-223 037 Page 40 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 47: Troubleshooting

    8-11. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10). Engine speed is controlled by an electronic governor and throttle actuator. Governor adjustment should only be done by a Factory Authorized Service Agent. A. Welding Trouble No weld output;...
  • Page 48 Trouble Check fuse F1, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check vol- tage regulator module PC3. Reset supplementary protector CB3 (see Section 8-9). 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 and isolation transformer ceptacles.
  • Page 49 Trouble Engine suddenly stops. Close engine access door. Engine access door switch LS1 prevents engine from starting or running if door is open Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high (see Section 5-6).

  • Page 50: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator OM-223 037 Page 44...
  • Page 51 222 966--C OM-223 037 Page 45...

  • Page 52: Section 10 − Run-In Procedure

    SECTION 10 − RUN-IN PROCEDURE 10-1. Wetstacking OM-223 037 Page 46 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. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and...

  • Page 53: Run-In Procedure Using Load Bank

    10-2. Run-In Procedure Using Load Bank Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. 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.

  • Page 54: Run-In Procedure Using Resistance Grid

    10-3. Run-In Procedure Using Resistance Grid OM-223 037 Page 48 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. 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.

  • Page 55: Section 11 − Generator Power Guidelines

    SECTION 11 − GENERATOR POWER GUIDELINES 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 GND/PE Generator Power Receptacles −...

  • Page 56: Grounding When Supplying Building Systems

    11-3. Grounding When Supplying Building Systems 11-4. How Much Power Does Equipment Require? OM-223 037 Page 50 GND/PE VOLTS 115 AMPS Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. Ground Device Use ground device as stated in electrical codes.
  • Page 57 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 58 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 59 11-8. Power Required To Start Motor Motor Start Code KVA/HP 11-9. How Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements 10.0 AC MOTOR VOLTS AMPS CODE PHASE 11.2 12.5 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
  • Page 60 11-10. Typical Connections To Supply Standby Power Utility Electrical Transfer Switch Service Essential Loads OM-223 037 Page 54 Fused Welding Disconnect Generator Switch Output (If Required) Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install and ground this equipment according to its Owner’s Manual and na-...
  • Page 61 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads 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 If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 62: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 110−Fig.12−5 109−Fig.12−3 100−Fig.12−2 OM-223 037 Page 56 Figure 12-1. Main Assembly...
  • Page 63 Fig. 12−4 804 069-F OM-223 037 Page 57...
  • Page 64 Item Dia. Part Mkgs....+213488 ....223005 .
  • Page 65 Item Dia. Part Mkgs....217387 ....218303 .
  • Page 66 Item Dia. Part Mkgs....213668 ....224266 .
  • Page 67 Item Dia. Part Mkgs. Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 100) ....097926 ....072590 .
  • Page 68 Item Dia. Part Mkgs. Figure 12-2. Panel, Front w/Components (Continued) ... . . 212436 ....039047 .
  • Page 69 Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. Item Dia. Part Mkgs. Figure 12-3. Control Panel (Figure 12-1 Item 109) ....220981 .
  • Page 70 Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. Item Dia. Part Mkgs..ROTOR . . . 212474 ....053390 .
  • Page 71 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. Item Dia. Part Mkgs..... 217081 .
  • Page 72 Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components sepa- rately or as part of the associated wiring harness. Item Dia. Part Mkgs..... 223030 .
  • Page 73 Notes MATERIAL THICKNESS GAUGE OM-223 037 Page 67...
  • Page 74 Notes Start Your Professional Over 80,000 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! trained since 1930! 1-800-332-9448 www.welding.org OM-223 037 Page 68...
  • Page 75 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.
  • Page 76 For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © 2007 Miller Electric Mfg. Co. 2007−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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