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Big Blue 350, 350X
PipePro Series And Big
Blue 350 PipePro SF
®
OM-262506H
Processes
Description
Engine Driven Welder/Generator
®
Mitsubishi
2016−11
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 PipePro Series

  • Page 1 Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welder/Generator Big Blue 350, 350X ® PipePro Series And Big Blue 350 PipePro SF ® Mitsubishi For product information, File: Engine Drive Owner’s Manual translations, and more, visit...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS 6-8. Remote Voltage/Amperage Control ............6-9.
  • Page 5: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury.
  • Page 6 D Be alert that welding sparks and hot materials from welding can FLYING METAL or DIRT can injure easily go through small cracks and openings to adjacent areas. eyes. D Watch for fire, and keep a fire extinguisher nearby. D Welding, chipping, wire brushing, and grinding D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause sparks and flying metal.
  • Page 7: Engine Hazards

    1-3. Engine Hazards EXHAUST SPARKS can cause fire. BATTERY EXPLOSION can injure. D Do not let engine exhaust sparks cause fire. D Always wear a face shield, rubber gloves, and D Use approved engine exhaust spark arrestor in protective clothing when working on a battery. required areas —...
  • Page 8: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and MOVING PARTS can injure. gouging can cause fire or explosion. D Keep away from moving parts such as fans, D Do not cut or gouge near flammables. belts and rotors. D Watch for fire; keep extinguisher nearby. D Keep all doors, panels, covers, and guards closed and securely in place.
  • Page 9 BATTERY CHARGING OUTPUT and BATTERY STATIC (ESD) can damage PC boards. EXPLOSION can injure. D Put on grounded wrist strap BEFORE handling Battery charging not present on all models. boards or parts. D Use proper static-proof bags and boxes to D Always wear a face shield, rubber gloves, and store, move, or ship PC boards.
  • Page 10: California Proposition 65 Warnings

    1-6. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...
  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 D Utiliser une protection différentielle lors de l’utilisation d’un équi- LES ACCUMULATIONS DE GAZ pement auxiliaire. Ne pas tester ni réarmer les prises femelles risquent de provoquer des blessures avec différentiel au régime de ralenti/en basse tension: cela ou même la mort. endommagerait le disjoncteur différentiel, qui ne remplirait plus son rôle de protection contre une électrocution causée par un D Fermer l’alimentation du gaz comprimé...
  • Page 13: Dangers Existant En Relation Avec Le Moteur

    D Porter un équipement de protection pour le corps fait d’un matériau Si des BOUTEILLES sont endomma- résistant et ignifuge (cuir, coton robuste, laine). La protection du gées, elles pourront exploser. corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.
  • Page 14: Dangers Liés À L'air Comprimé

    D Pour empêcher tout démarrage accidentel pendant les travaux D Toujours vérifier le niveau de liquide de refroidissement dans le d’entretien, débrancher le câble négatif (−) de batterie de la borne. vase d’expansion (si présent), et non dans le radiateur (sauf si pré- cisé...
  • Page 15: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Pour rechercher des fuites, utiliser de l’eau savonneuse ou D Ne pas approcher les mains, cheveux, vêtements lâches et outils un détecteur à ultrasons, jamais les mains nues. En cas des organes mobiles. de détection de fuite, ne pas utiliser l’équipement. D Avant d’intervenir sur le circuit d’air comprimé, couper l’alimentation électrique, verrouiller et étiqueter l’appareil, D Remettre les portes, panneaux, recouvrements ou dispositifs...
  • Page 16 D Réduire le courant ou le facteur de marche avant de poursuivre le LA SORTIE DE RECHARGE et L’EXP- soudage. LOSION DE LA BATTERIE peuvent D Ne pas obstruer les passages d’air du poste. provoquer des blessures. LES CHARGES ÉLECTROSTATI- La recharge de batterie n’existe pas sur tous les QUES peuvent endommager les modèles.
  • Page 17: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements Pour les moteurs à essence : Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques Les gaz d’échappement des moteurs contiennent des pro- dont l’État de Californie reconnaît qu’ils provoquent des mal- duits chimiques dont l’État de Californie reconnaît qu’ils formations congénitales et, dans certains cas, des cancers.
  • Page 18 OM-262 506 Page 14...
  • Page 19: Section 3 − Definitions

    Complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012−05 Protect yourself from electric shock by insulating yourself from work and ground.
  • Page 20 Complete Parts List is available at www.MillerWelds.com Do not work on unit if engine is running. Stop engine first. Safe21 2012−05 Do not smoke while fueling or if near fuel. Safe22 2012−05 Stop engine before fueling. Safe23 2012−05 Do not fuel a hot engine. Safe24 2012−05 Use lift eye to lift unit and properly installed accessories only, not gas cylinders.
  • Page 21 Complete Parts List is available at www.MillerWelds.com Engine fuel plus flames or sparks can cause fire. Safe45 2012−05 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. Safe46 2012−05 Read Owner’s Manual. Read labels on unit. Safe47 2012−05 Read Owner’s Manual.
  • Page 22: Miscellaneous Symbols And Definitions

    Complete Parts List is available at www.MillerWelds.com 3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Tungsten Inert Amperage Seconds Gas (TIG) Lift-Arc Starting Aid Voltage Percent (Preheat) Suitable For Welding In An Engine Environment With Increased Risk Of Electric Shock Engine...
  • Page 23 Complete Parts List is available at www.MillerWelds.com Certified/Trained Manual Cleaning Check Air Filter Mechanic Check Call for Spark Arrestor Injectors/Pump Maintenance Check Valve Air Filter Clearance Notes OM-262506 Page 19...
  • Page 24: Section 4 − Specifications

    Complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated output.
  • Page 25: Duty Cycle And Overheating

    Complete Parts List is available at www.MillerWelds.com 4-5. Duty Cycle And Overheating 100% Duty Cycle Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. This unit is rated for welding at 325 amperes continuously. For best performance when welding above 300 amperes, place Engine Control switch in...
  • Page 26: Volt-Ampere Curves For All Models

    Complete Parts List is available at www.MillerWelds.com 4-6. Volt-Ampere Curves For All Models The volt-ampere curves show the A. Stick Mode minimum and maximum voltage and amperage output capabilities of the welder/generator. Curves of all other settings fall between the curves shown.
  • Page 27: Fuel Consumption For All Models

    Complete Parts List is available at www.MillerWelds.com 4-7. Fuel Consumption For All Models The curve shows typical fuel use under weld or power loads. 2.00 1.75 1.50 1.25 1.00 0.75 0.50 IDLE 0.25 0.00 DC Weld Amperes At 100% Duty Cycle 247 984-A 4-8.
  • Page 28 Complete Parts List is available at www.MillerWelds.com Notes OM-262506 Page 24...
  • Page 29: Section 5 − Installation

    Complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Installing Welder/Generator Airflow Clearance 18 in. Movement (460 mm) 18 in. 18 in. (460 mm) (460 mm) 18 in. 18 in. (460 mm) (460 mm) Location/Mounting Bolting Welding Unit In Unit In Place...
  • Page 30: Installing Exhaust Pipe

    Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator To Truck Or Trailer Frame GND/PE rot_grnd2 2014−11 − 800 652-D frame. Always connect a ground Equipment Grounding Terminal (On Always ground generator frame to wire from the generator equipment Front Panel) vehicle frame to prevent electric grounding terminal to bare metal on...
  • Page 31: Connecting The Battery

    Complete Parts List is available at www.MillerWelds.com 5-4. Connecting The Battery − Shown with door open and Tools Needed: rocker panel removed. 1/2 in. Conn_Batt2 2014−11 / S-0756-C / 161-002 NOTICE − Lead acid batteries discharge NOTICE − Wait two minutes after engine Never start the engine when the when stored in any temperature.
  • Page 32: Engine General Information

    Keep battery in good condition. Store bat- Automatic Shutdown System tery in warm area. NOTICE − Diesel engines in Miller equip- Automatic shutdown system stops en- Use fuel formulated for cold weather (die- gine if oil pressure is too low or coolant ment are meant to operate optimally at sel fuel can gel in cold weather).
  • Page 33: Engine Oil Prestart Information

    Complete Parts List is available at www.MillerWelds.com 5-7. Engine Oil Prestart Information Check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label). Full 907 427-6 5-8. Connecting To Weld Output Terminals Stop engine.
  • Page 34: Weld Output Terminals

    Complete Parts List is available at www.MillerWelds.com 5-9. Weld Output Terminals A. Big Blue 350 PipePro And Big Blue 350X PipePro Models 256 735-A Stick Welding MIG And FCAW Welding Turn off power before connecting to weld output terminals. For Stick welding Direct Current Electrode For MIG and FCAW welding Direct Current Positive (DCEP), connect electrode holder Electrode Positive (DCEP), connect wire...
  • Page 35 Complete Parts List is available at www.MillerWelds.com B. Big Blue 350 PipePro SF Models Ac.c Ac.c flashes when the Smart Feeder is not weld- ing or when the In Use light on the smart feeder is OFF. Smart Feeder will connect. VRD Switch inside unit MUST be OFF to connect in STICK.
  • Page 36: Selecting Cable Sizes

    **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. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-L 2015−02 5-11. Connecting To Remote 14 Receptacle RC14...
  • Page 37: Section 6 − Operating Welder/Generator

    Complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATING WELDER/GENERATOR 6-1. Front Panel Controls (See Section 6-2) North American Auxiliary Power Panel Shown. 273 318-A / 256 735-A / 907 428−1 OM-262506 Page 33...
  • Page 38: Description Of Front Panel Controls (See Section 6-1)

    (110°C). trol switch in Run position. To set voltage, turn Process/Contactor switch Weld Controls NOTICE − Diesel engines in Miller equipment to MIG or FCAW position. Turn V/A control Remote Control Receptacle are meant to operate optimally at moderate to...
  • Page 39: Process/Contactor Switch

    Complete Parts List is available at www.MillerWelds.com 6-3. Process/Contactor Switch Process/Contactor Switch Weld output terminals are ener- gized when Process/Contactor switch is in an Electrode Hot posi- tion and the engine is running. Use switch to select weld process and weld output on/off control (see table be- low).
  • Page 40: Arc Control

    Complete Parts List is available at www.MillerWelds.com 6-4. Arc Control Arc Control Stick Control adjusts Dig when Stick is se- lected on mode switch. When control is set toward minimum, short-circuit amperage at low arc voltage is the same as normal weld- ing amperage.
  • Page 41: Low Open-Circuit Voltage (Vrd) Switch Mode

    Complete Parts List is available at www.MillerWelds.com 6-5. Low Open-Circuit Voltage (VRD) Switch Mode Voltage Reducing Device (VRD) Switch The VRD switch can be set for low open-circuit voltage operation in Stick mode. When the unit is con- figured for low open-circuit voltage operation only a low sensing voltage (approximately 15 volts DC) is present between the elec-...
  • Page 42: Lift-Arct Tig With Auto-Stopt

    Complete Parts List is available at www.MillerWelds.com 6-7. Lift-Arct TIG With Auto-Stopt Arc Start With Lift-Arc TIG Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted. Arc Start With Lift-Arc Select Lift-Arc TIG at Process/ Contactor switch.
  • Page 43: Remote Voltage/Amperage Control

    Complete Parts List is available at www.MillerWelds.com 6-8. Remote Voltage/Amperage Control Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-11). When a remote control is connected to the Remote receptacle, the Auto Sense Re- mote feature automatically switches volt- age/amperage control to the remote con- trol.
  • Page 44: Fuel/Hour Gauge Descriptions

    Complete Parts List is available at www.MillerWelds.com 6-9. Fuel/Hour Gauge Descriptions OM-262506 Page 40...
  • Page 45: Operating Optional Engine Block Heater

    Complete Parts List is available at www.MillerWelds.com 6-10. Operating Optional Engine Block Heater Engine Block Heater Plug Use heater to maintain a constant engine coolant temperature. To turn on heater, connect heater Coolant Heater plug to 120 volts AC receptacle. Specifications Do not run engine while en- ±...
  • Page 46: Section 7 − Operating Auxiliary Equipment

    Complete Parts List is available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles 263 481-A overload. If CB5 opens, the receptacles do Use GFCI protection when operat- Test GFCI monthly. See Section 7-3 not work. Place CB5 switch in On position ing auxiliary equipment.
  • Page 47: Export Auxiliary Power Receptacles

    Complete Parts List is available at www.MillerWelds.com 7-2. Export Auxiliary Power Receptacles 256 593-A switch in On position to reset circuit break- Use GFCI protection when operating Test GFCI monthly. See Section 7-3 auxiliary equipment. If unit does not for GFCI information and for reset- have GFCI receptacles, use GFCI- ting and testing procedures.
  • Page 48: Gfci Receptacle Information, Resetting And Testing

    Complete Parts List is available at www.MillerWelds.com 7-3. GFCI Receptacle Information, Resetting And Testing Test and reset GFCI only at Run speed. RotGFCI1 2014−09 If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles Use GFCI protection when operating button pops out, and the circuit opens to dis- auxiliary equipment.
  • Page 49: Section 8 − Maintenance & Troubleshooting

    Complete Parts List is available at www.MillerWelds.com SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Maintenance Label 239 396-K OM-262506 Page 45...
  • Page 50: Routine Maintenance

    Complete Parts List is available at www.MillerWelds.com 8-2. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions. n = Check Z = Change ~ = Clean l = Replace...
  • Page 51: Checking Generator Brushes

    Complete Parts List is available at www.MillerWelds.com 8-4. Checking Generator Brushes Stop engine and let cool. Generator Brush Assembly Mark and disconnect leads at brush hold- er assembly. Remove assembly. Press on brush to be sure springs compress. Replace Assembly if Replace assembly if brushes are dam- Brushes are Damaged aged or if brush material is at or near mini-...
  • Page 52: Servicing Air Cleaner

    Complete Parts List is available at www.MillerWelds.com 8-7. Servicing Air Cleaner Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each...
  • Page 53: Inspecting And Cleaning Optional Spark Arrestor Muffler

    Complete Parts List is available at www.MillerWelds.com 8-8. Inspecting And Cleaning Optional Spark Arrestor Muffler 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 54: Overload Protection

    Complete Parts List is available at www.MillerWelds.com 8-10. Overload Protection Stop engine. When a circuit breaker, supple- mentary protector, or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. Fuse F1 F1 protects the stator exciter winding from overload.
  • Page 55 Complete Parts List is available at www.MillerWelds.com 8-11. Servicing Fuel And Lubrication Systems Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop en- gine, tighten connections as necessary, and wipe up spilled Tools Needed: fuel.
  • Page 56: Voltmeter/Ammeter Help Displays

    Complete Parts List is available at www.MillerWelds.com 8-12. Voltmeter/Ammeter Help Displays Use the Voltmeter/Ammeter help displays to diagnose and correct fault conditions. HL.P When a help code is displayed normally weld output has stopped but generator power output may be okay. To reset help displays, stop unit and then restart.
  • Page 57: Troubleshooting

    Complete Parts List is available at www.MillerWelds.com 8-13. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-12). A. Welding Trouble Remedy No weld output; generator power output Have Factory Authorized Service Agent check main rectifier and main control module PC1. okay at AC receptacles.
  • Page 58 Complete Parts List is available at www.MillerWelds.com Trouble Remedy Smart Feeder displays PoL Err. This is a Polarity Error. Ensure the positive (+) stud on the power source is connected to the electrode stud on the Smart Feeder and the negative (−) stud on the power source is connected to the work stud on the Smart Feeder.
  • Page 59: Section 9 − Parts List

    Complete Parts List is available at www.MillerWelds.com Trouble Remedy Engine hard to start in cold weather Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow (continued). plug. Engine suddenly stops. Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high (see Sections 5-6 and 5-7).
  • Page 60: Section 10 − Electrical Diagrams

    SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welder/Generator OM-262506 Page 56...
  • Page 61 271 271-D OM-262506 Page 57...
  • Page 62: Section 11 − Run-In Procedure

    2014−09 NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.
  • Page 63: Run-In Procedure Using Load Bank Or Resistance Grid

    11-2. Run-In Procedure Using Load Bank Or Resistance Grid S-0683 / S-0684 Stop engine. Weld Cables voltage and current of the generator (see nameplate, rating label, or the Resistance Grid Do not touch hot exhaust pipe, en- specifications section in this manual). gine parts, or load bank/grid.
  • Page 64: Section 12 − Generator Power Guidelines

    SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 12-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
  • Page 65 12-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. GND/PE Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
  • Page 66 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 67 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in. 3/8 in. 1/2 in. Circular Saw 6-1/2 in. 7-1/4 in. 8-1/4 in. 1400 1400 Table Saw 9 in. 4500 1500 10 in. 6300 1800 Band Saw 14 in.
  • Page 68 12-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 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 69 12-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install, ground, and operate this equipment ac- cording to its Owner’s Manu- al and national, state, and lo- cal codes.
  • Page 70 12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten- sion cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts)
  • Page 71 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 72 Contact the Delivering Carrier to: 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2016 Miller Electric Mfg. Co. 2016−01...

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Big blue 350Big blue 350xBig blue 350 pipepro sf

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