Miller Electric Big Blue 400 PX Owner'S Manual Download Page 3

Page: 3 / 76

TABLE OF CONTENTS

SECTION 1

−

SAFETY PRECAUTIONS

−

READ BEFORE USING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Engine Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Compressed Air Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Additional Symbols For Installation, Operation, And Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. California Proposition 65 Warnings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. Principal Safety Standards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-8. EMF Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2

−

CONSIGNES DE SÉCURITÉ

−

LIRE AVANT UTILISATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers existant en relation avec le moteur

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Dangers liés à l’air comprimé

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

. . . . . .

2-6. Proposition californienne 65 Avertissements

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Principales normes de sécurité

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Information EMF

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3

−

DEFINITIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Warning Label Definitions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Manufacturer’s Rating Label

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Symbols And Definitions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4

−

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Weld And Power Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Engine Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Dimensions, Weights, And Operating Angles

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Volt-Ampere Curves

−

50 Hz Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Volt-Ampere Curves

−

60 Hz Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Fuel Consumption

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Duty Cycle And Overheating

−

50 Hz Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Duty Cycle And Overheating

−

60 Hz Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. AC Generator Power Curve

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5

−

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Mounting Welding Generator

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Installing Exhaust Pipe

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Activating The Dry Charge Battery (If Applicable)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Connecting The Battery

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Engine Prestart Checks

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Connecting To Weld Output Terminals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Selecting Weld Cable Sizes*

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Connecting To Remote 14 Receptacle RC14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Gas Connections

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6

−

OPERATING WELDING GENERATOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Front Panel Controls (See Section 6-2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Description Of Front Panel Controls (See Section 6-1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Process/Contactor Switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Remote Voltage/Amperage Control

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7

−

OPERATING AUXILIARY EQUIPMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. 110 Volt Receptacles

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for Big Blue 400 PX

Page 1: ...rocesses Description Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding Engine Driven Welding Generator TIG GTAW Welding MIG GMAW Welding Flux Cored FCAW Welding 50 60 Hz Visit our website at www MillerWelds com File Engine Drive ...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operatio...

Page 3: ...initions 14 SECTION 4 SPECIFICATIONS 15 4 1 Weld And Power Specifications 15 4 2 Engine Specifications 15 4 3 Dimensions Weights And Operating Angles 15 4 4 Volt Ampere Curves 50 Hz Operation 16 4 5 Volt Ampere Curves 60 Hz Operation 17 4 6 Fuel Consumption 18 4 7 Duty Cycle And Overheating 50 Hz Operation 18 4 8 Duty Cycle And Overheating 60 Hz Operation 19 4 9 AC Generator Power Curve 19 SECTION...

Page 4: ...estor Muffler 37 8 7 Servicing Engine Cooling System 37 8 8 Servicing Fuel And Lubrication Systems 38 8 9 Overload Protection 39 8 10 Optional Voltmeter Ammeter Help Displays 40 8 11 Troubleshooting 41 SECTION 9 ELECTRICAL DIAGRAMS 44 SECTION 10 RUN IN PROCEDURE 46 10 1 Wetstacking 46 10 2 Run In Procedure Using Load Bank 47 10 3 Run In Procedure Using Resistance Grid 48 SECTION 11 GENERATOR POWER...

Page 5: ... 73 23 EEC 2006 95 EC 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 Noise level of Welding Generators 2000 14 EC CE Marking Directive 93 68 EEC Standards Arc Welding Equipment Part 1 Welding Power Sources IEC 60974 1 Ed 3 2005 07 Rotating Electrical Machines Part 1 Rating and Performance IEC 60034 1 Ed...

Page 6: ...eo 6 E Cheadle Heath 20098 San Giuliano Stockport Chesire SK30XU Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 European Contact Signature The Manufacturer Declares the Big Blue 400 PX Conforms to Directive 2000 14 EC Noise Level of Welding Generators Effective Date 7 2004 Sound Level Information Measured Sound Power Level 97 dB Guaranteed Sound Power Level 98 dB Sound power level requireme...

Page 7: ...igh risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop...

Page 8: ...lding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may cont...

Page 9: ...arts bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can burn If possible check coolant level when engine is cold to avoid scalding Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance se...

Page 10: ...tage and frequency caused by low engine speed damage electric motors Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury Wear a face shield to protect eyes and face Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection Sparks can cause fires keep flammables away MOVING...

Page 11: ...tec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from CanadianStandards Association Standard...

Page 12: ...n est équipé Des précautions de sécurité supplémentaires sont requises dans des environnements à risque comme les endroits humides ou lorsque l on porte des vêtements mouillés sur des structures mé talliques au sol grillages et échafaudages dans des positions assises à genoux et allongées ou quand il y a un risque important de contact accidentel avec la pièce ou le sol Dans ces cas utiliser les ap...

Page 13: ...é Porter des lunettes de sécurité avec écrans latéraux même sous votre casque Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles prévenir toute personne sur les lieux de ne pas regarder l arc Porter des vêtements confectionnés avec des matières résistan tes et ignifuges cuir coton lourd ou laine et des botte...

Page 14: ...ur les batteries Débrancher le câble négatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein Ne pas faire le plein en fumant ou proche d une source d étincelles ou d une flamme nue Ne pas faire le plein de carburant à ras bord prévoir de l espace pour son e...

Page 15: ...ant de changer ou de rajouter des éléments ou avant d ouvrir la purge ou le bouchon de remplissage d huile Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion Ne pas couper ou gouger à proximité de pro duits inflammables Surveillez et garder un extincteur à proximité DES PIECES CHAUDES peuvent provo quer des brûlures et blessures Ne pas toucher le compres...

Page 16: ...TIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil N utiliser que les pièces de rechange recom mandées par le constructeur Effectuer la maintenance et le service du moteur et du compres seur d air suivant les instructions dans ce manuel ou le manuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences Le...

Page 17: ... Standards Institute 11 West 43rd Street New York NY 10036 8002 téléphone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 téléphone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title...

Page 18: ...e possible hazards as shown by the symbols Read Owner s Manual Follow instructions to activate battery 5 Check oil level Add oil if necessary 6 During the first 50 hours of operation keep welding load above 200 amperes Do not weld below 200 amperes of output 7 After the first 50 hours of operation change the oil and oil filter 2 1 4 DIESEL API CD MIL L 2104D CD SE CD SF 3 S 177 571 0 50 h Std 0 20...

Page 19: ...OM 223 037 Page 13 3 2 Manufacturer s Rating Label 223 081 A Ref 804 068 E ...

Page 20: ...ature Output Alternating Current Stick SMAW Welding Constant Current CC MIG GMAW Welding TIG GTAW Welding Time h Hours s Seconds 1 Single Phase 3 Three Phase Read Operator s Manual Circuit Protector Do Not Switch While Welding Electrode Connection Work Connection 3 G Engine Driven Three Phase Alternator With Rectifier Hz Hertz X Duty Cycle U0 Rated No Load Voltage Average U2 Conventional Load Volt...

Page 21: ...cle 73 110 55 V AC Receptacles 7 kVA kW 4 2 Engine Specifications Engine Fuel Capacity C C Perkins 403 15 Water Cooled Three Cylinder 21 7 HP Diesel Engine 11 5 gal 43 5 L Perkins 403 15 Water Cooled Three Cylinder 21 7 HP Diesel Engine 11 5 gal 43 5 L 4 3 Dimensions Weights And Operating Angles Dimensions Height 32 in 813 mm 35 3 4 in 908 mm to top of lift eye G Width 26 1 4 in 667 mm mtg bracket...

Page 22: ...t capabilities of the welding generator Curves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode 0 10 20 30 40 50 60 70 80 90 100 0 100 2 00 300 400 500 DC AMPERES DC VO LT S MIN 200 300 0 20 40 60 80 100 0 100 200 300 400 500 MAX MIN 0 20 40 60 80 100 0 100 200 300 400 50 0 MIN 200 300 DC VO LT S DC VO LT S DC AMPERES DC AMPERES ...

Page 23: ...capabilities of the welding generator Curves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode DC VOLTS DC AMPERES 0 100 200 300 400 500 100 80 60 40 20 0 MIN MAX 300 0 10 20 30 40 50 60 70 80 90 100 0 100 2 00 300 400 500 DC AMPERES DC VO LT S MIN 300 MAX 0 100 200 300 400 500 MIN MAX DC VO LT S 20 40 60 80 100 0 DC AMPERES ...

Page 24: ...HZ U S GAL HR 0 00 0 25 0 50 0 75 1 00 1 25 1 50 1 75 2 00 0 50 100 150 200 250 300 350 400 4 7 Duty Cycle And Overheating 50 Hz Operation 100 Duty Cycle At 250 Amperes Continuous Welding Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty 223 179 A ...

Page 25: ...Welding Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty 4 9 AC Generator Power Curve 223 185 A The ac power curve shows the gen erator power in amperes 0 20 40 60 80 100 120 0 20 40 60 80 100 120 140 A C VOLTS 0 10 20 30 40 50 60 70 A C A MPERES IN 22 0V MODE 0 40 80 1 20 1 60 2 00 2 40 AC AM...

Page 26: ...Section 5 2 for mounting information Grounding 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Electrically bond generator frame to vehicle frame by met al to metalcontact Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire Bed liners shipping skids and some running gears insu late the we...

Page 27: ...rackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 8 16 x 1 in Screws Supplied To Bolt Unit In Place Remove hardware securing the four mounting brackets to the base Reverse brackets and reattach to base with original hardware Mount unit to truck or trailer with 1 2 in 12 mm or large...

Page 28: ...ols Needed 803 582 G Ref 222 875 A Stop engine and let cool Point exhaust pipe in desired di rection but always away from front panel and direction of travel Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 29: ... lyte to raise to proper level Reins tall vent caps 8 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am peres Disconnect charging cables and install battery When electrolyte is low add only distilled water to cells to maintainproper level 1 Tools Needed 2 4 30 A For 12 Minutes 5 A For 30 Minutes OR 3 dr...

Page 30: ... oil see maintenance label Coolant Check coolant level in radiator before start ing unit the first time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check coolant level in recovery tank daily If necessary add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels If recovery tank coolant level was low also check coolant level ...

Page 31: ...minal and copper bar are clean 7 5 6 Do not place anything between Correct Installation Incorrect Installation 4 weld cable terminal and copper bar Stick and TIG Welding For Stick and TIG welding Direct Cur rent Electrode Positive DCEP con nect electrode holder cable to CC Stick TIG terminal on right and work cable to Negative terminal on left For Direct Current Electrode Nega tive DCEN reverse ca...

Page 32: ...1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 2 ea 4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 2 ea 4 0 2x120 500 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 3 ea 3 0 3x95 3 ea 3 0 3x95 This chart is a general guideline and may not ...

Page 33: ...m min to max of remote control with Voltage Amperage Adjust control at max OR F Current feedback 1 volt per 100 amperes OR H Voltage feedback 1 volt per 10 arc volts GND K Chassis common Ref 804 068 The remaining sockets are not used NEUTRAL G Circuit common for 24 volt ac circuit 5 10 Gas Connections 804 068 1 Gas Fitting Fittings have 5 8 18 right hand threads 2 Cylinder Valve Open valve slightl...

Page 34: ...OM 223 037 Page 28 SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls See Section 6 2 218 379 A Ref 804 068 804 009 A 1 2 7 6 8 9 10 11 12 4 Stop 3 5 ...

Page 35: ...ressure is below 10 psi 69 kPa Normal engine temperature is 180 203 F 82 95 C Normal oil pressure is 30 60 psi 207 414 kPa NOTICE Do not run engine until trouble is fixed Weld Controls 8 Remote Control Receptacle Use receptacle to connect remote controls and wire feeders When a remote control is connected to the Remote receptacle the Auto Sense Remote feature automatically switches voltage am pera...

Page 36: ...unning Ref 804 068 Ref 222 875 1 Process Contactor Switch Settings Switch Setting Process Output On Off Control Switch Setting Process Output On Off Control Remote On Off Switch Required TIG GTAW With HF Unit Pulsing Device Or Remote Control At Remote 14 Receptacle Remote On Off Switch Required Stick Stick SMAW With Remote On Off At Remote 14 Receptacle Remote On Off Switch Required CV Feeder Usin...

Page 37: ... Process Contactor switch Ref 222 875 Ref 804 068 1 Adjust Optional Remote Control to 100 Set V A Control To Desired Maximum Weld Output Using Weld Meters Set TIG or STICK Process In Example Min 20 A DC Max 205 A DC Max 205 A DC Min 20 A DC Connect Remote Control To Remote Receptacle RC14 Adjust Optional Remote Control to desired weld output Weld meters will always show the combined main and remot...

Page 38: ...s RC13 from overload If a supplemen tary protector opens the receptacle does not work Place supplementary protector switch in the On position to reset breaker 6 Earth Leakage Circuit Breaker ELCB 1 7 Earth Leakage Circuit Breaker ELCB2 8 Circuit Breaker Test Button ELCB1 protects RC12 and RC13 from Earth leakage fault ELCB2 protects RC11 from overload and Earth leakage fault If ei ther circuit bre...

Page 39: ... To be done by Factory Authorized Service Agent Reference Every 8 Hours Section 8 7 8 8 Coolant Level Fuel Level Oil Level Oil Fuel Spills Every 50 Hours Section 8 5 Air Cleaner Element Weld Terminals Every 100 Hours Battery Terminals Air Cleaner Hoses Every 250 Hours 1 2 in 13 mm Engine Manual Section 8 6 8 8 Unreadable Labels Fan Belt Tension Oil Oil Filter Spark Arrestor Every 500 Hours Section...

Page 40: ...OM 223 037 Page 34 8 2 Maintenance Label ...

Page 41: ... or distributor 2 If your problem cannot be resolved at the dealer or distributor level without additional assistance contact the Perkins Technical Support Center through the Perkins website Please follow the above steps in sequence if a problem arises Website Address www Perkins com 8 4 Checking Generator Brushes Ref 222 875 S 0233 A Stop engine and let cool 1 Generator Brush With Spring Mark and...

Page 42: ...safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearly or after six cleanings 1 Housing 2 Safety Element Optional 3 Primary Element 4 Dust Cap 5 Dust Ejector To clean air filter Wipe off cap and housing Remove cap and dump out dust Remove element s W...

Page 43: ...er end of exhaust pipe with fireproof material Stop engine and let cool Reinstall cleanout plug Tools Needed 3 8 in 1 2 3 8 7 Servicing Engine Cooling System 804 009 A Ref 222 875 Stop engine and let cool 1 Radiator Draincock 2 Radiator Cap Cover Change coolant according to engine manual Add coolant according to Sec tion 5 6 Run engine until engine reaches normal operating temperature Check coolan...

Page 44: ...all new filter and turn clock wise Inspect fuel lines and replace if cracked or worn To drain water from fuel system See engine manual To replace secondary in line fuel filter Note direction of fuel flow as indi cated by arrow on side of filter Re move fuel line clamps and discon nect fuel lines from fuel filter Re place filter reconnect fuel lines and reinstall clamps To drain sludge from fuel ta...

Page 45: ...ker CB1 Not Shown 3 Supplementary Protector CB2 4 Supplementary Protector CB3 5 Supplementary Protector CB8 CB1 protects the engine battery cir cuit If CB1 opens the engine will not crank CB1 automatically resets when the fault is corrected CB2 protects the engine wiring har ness If CB2 opens the engine will not crank CB3 protects part of the weld control wiring harness If CB3 opens weld and gener...

Page 46: ...duty cycle Keep en gine access door closed when run ning to maintain proper cooling air flow past rectifier Allow unit to cool before restarting If problem contin ues have Factory Authorized Ser vice Agent check unit 4 Help 23 Display Indicates one of the rectifier output SCR s has failed If this display is shown have Factory Authorized Service Agent check the rectifier SCR s 5 Help 24 Display Ind...

Page 47: ...regulator module PC3 and field excitation circuit Erratic weld output Check and tighten connections inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Have Factory Authorized Service Agent check main control module P...

Page 48: ... Check battery connections and clean and tighten if necessary Circuit breaker CB1 may be open CB1 automatically resets when fault is corrected see Section 8 9 Have Factory Authorized Service Agent check engine wiring harness and components Reset supplementary protector CB2 see Section 8 9 Check engine wiring harness plug connections Have Factory Authorized Service Agent check Engine Control switch...

Page 49: ...e if speed is too high The overspeed shutdown system resets when the engine is restarted An overspeed condition can also occur if the engine draws fuel rich air from the surrounding atmo sphere oil refineries Have Factory Authorized Service Agent check Engine Control switch S1 control relay CR1 inte grated rectifier SR2 fuel pump and engine governor system See engine manual Engine slowly stopped a...

Page 50: ...OM 223 037 Page 44 SECTION 9 ELECTRICAL DIAGRAMS Figure 9 1 Circuit Diagram For Welding Generator ...

Page 51: ...OM 223 037 Page 45 222 966 C ...

Page 52: ...ings seat faster if engine runs at weld power rpm and the welding generator is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run in if the engine is run too long at light load or idle rpm If exhaust pipe is coated with a wet black tar like substance dry the engine using one of the following run in procedures See the engin...

Page 53: ...enerator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust generator A V control so load equals rated voltage and current of generator see name plate rating label or the specifi cations section in this manual Check generator and load bank meters after first five minute...

Page 54: ...c tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then ad just generator A V control so load equals rated voltage and current of the generator see nameplate rating label or the specifications section in this manual Check generator and meters after first f...

Page 55: ...lectric shock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire Electrically bond generator frame to vehi...

Page 56: ...ive load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 11 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run n...

Page 57: ...m Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 ...

Page 58: ...1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500...

Page 59: ...t must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 kVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes VOLTS AMPS HP 230 2 5 1 4 Hz PHASE CODE 60 1 M AC MOTOR 1 2 3 4 11 9 How Much Power Can Generator Supply...

Page 60: ...ck to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring Co...

Page 61: ...50 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 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 Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Amperes Load Watts 4 6 8 10 12 14 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 2...

Page 62: ...less listed Wiring harnesses are listed at the end of parts section 109 Fig 12 3 1 110 Fig 12 5 106 6 7 4 8 9 10 12 13 11 14 15 105 103 102 17 18 19 20 21 92 93 85 84 83 82 81 86 87 91 90 89 88 96 97 99 100 Fig 12 2 107 108 22 23 95 104 5 94 101 98 16 2 3 Figure 12 1 Main Assembly ...

Page 63: ... Page 57 804 069 F 55 74 76 75 77 78 79 80 73 71 68 67 66 65 63 55 57 56 59 58 62 61 60 36 37 38 39 40 43 44 49 50 51 45 52 53 54 47 46 45 32 33 34 31 30 29 28 27 26 24 64 72 70 35 111 69 112 48 41 25 42 Fig 12 4 ...

Page 64: ...ngine 1 21 213580 Pipe Exhaust Spark Arrestor 1 22 088528 Spark Arrestor Exhaust 1 23 201399 Pipe Exhaust Extension 5 0 Long 1 24 213470 Cover Top 1 222999 Foam Acoustical Top Cover 1 223001 Foam Acoustical Top Cover 1 049525 Nut 312 18 U nut Multi thread 8 25 233088 Label Danger Using A Generator Indoors Can Kill You In Minutes Unit 1 26 189052 Grommet Plastic Neck Filler Fuel 1 27 190198 Cap Tan...

Page 65: ...800 series 1 197899 Filter Oil Perkins 140516130 1 217695 Switch Coolant Temp N C 110c 1 66 212613 Hose Radiator Upper 1 67 216811 Clip Nut Retaining 2 68 197613 Air Cleaner Intake 5 250 In Includes 1 197675 Dust Ejector Air Cleaner 1 197676 Element Air Cleaner 1 197677 Cover Assy Air Cleaner 1 197678 Body Air Cleaner 1 197679 Element Air Cleaner Safety 1 197829 Bracket Mtg Air Cleaner 1 69 212617...

Page 66: ...ing 1 99 220955 Panel Front Access 1 100 Figure 12 2 Front Panel Assembly 1 101 CT1 202130 Xfmr Current Sensing 1 102 213504 Tray Reactor Rectifier 1 103 213500 Brkt Beam Support 1 104 T1 220887 Xfmr Isolation 1 105 TE1 172661 Block Stud Connection 6 Position 1 173734 Link Jumper 3 106 C11 217054 Capacitor Cer Disc 0047 Uf 3000 Vdc W Terms 1 107 R3 213027 Resistor WW Tap 300 W 40 Ohm 1 108 HD1 168...

Page 67: ...91 Conn Circ Ms Protective Cap Size 20 Nylon 1 4 206795 Boot Circuit Breaker Clear Hex Nut 1 5 097922 Knob Pointer 875 Dia X 250 Id W Set Screwsplstc 1 6 Nameplate Control Order By Model Serial No 1 7 PC6 223860 Circuit Card Assy Connector Receptacle 1 8 CB8 083432 Supplementary Pro Man Reset 1p 10a 250vac Frict 1 9 213655 Panel Front Engine Weld Control 1 10 214762 Bracket Meter Hole Cover 1 10 2...

Page 68: ... 083030 Stud Brs 250 20 X 1 750 W Hex Collar 1 30 010915 Washer Flat 257idx0 640odx 031t Brs 4 31 601836 Nut 250 20 50hex 19h Brs 3 32 220805 Nut 750 14 Nps 1 48hex 41h Nyl 2 33 RC11 156831 Rcpt Str 2p3w 32a 220v Flange Mtg 2 34 209056 Cover Receptacle W Gasket 1 35 Nameplate Weld Terminal Order By Model Serial No 1 36 181169 Spacer Output Stud 3 37 186621 Boot Generic Output Stud 3 38 180735 Wash...

Page 69: ...5a 6pin Flange 1 6 046432 Holder Fuse Mintr 250 X 1 250 Panel Mtg 1 7 F1 085874 Fuse Mintr Cer Slo blo 10 Amp 250 Volt 1 8 217335 Resistor Board 1 9 CR3 197325 Relay Encl 12vdc Spst 70a 4pin Flange Mtg 1 10 SR1 SR2 035704 Rectifier Integ Bridge 40 Amp 800v 2 11 CB2 CB3 083432 Supplementary Pro Man Reset 1p 10a 250vac Fric 2 12 222979 Bracket Mtg Governor Control Module 1 13 ENG CONTROLLER 222967 M...

Page 70: ...d Split 312 6 9 192686 Screw M 8 1 25x 25 Hex Hd pln 8 8 Pld Din933 6 10 212641 Stud Stl 375 16 1 625x 19 000 4 11 STATOR 222844 Stator Generator 4 Pole 50 60 hz 1 12 160943 Endbell 1 13 167788 Nut 375 16 56hex 34h Stl Pld Sem Cone Wshr 88d 4 14 218552 Brush Assembly 2 Pole Includes 1 15 047879 Bar Retaining Brushholder 2 Brushes 1 16 161306 Cap Brushholder 2 17 126984 Brush w Spring 2 18 005614 H...

Page 71: ...Kit Module SCR 3 3 MOD4 5 6 218292 Kit Module SCR 3 4 212602 Bus Bar Rectifier 1 5 212639 Bus Bar Rectifier 3 6 212601 Insulator Rectifier 1 7 TH1 213930 Thermistor Ntc 30k Ohm 25 Deg C 8 5in Lead 1 8 C1 6 215611 Capacitor Assy 3 9 C7 8 9 048420 Capacitor Cer Disc 01 Uf 1000 Vdc W Terms 3 10 217085 Bus Bar Rectifier 1 181853 Insulator Screw For Mounting Rectifier 4 To maintain the factory original...

Page 72: ...rance Lock 1 S5 011611 Switch Tgl Dpdt 15a 125vac On none on Spd Term Chr 1 129524 Term Frict 250x032 Uninsul Male 130 Stud Mtg 3pr 2 221864 Harness Weld Control CE Includes 1 PLG2 150316 Conn Rect Univ 039 6p S 3row Plug Cable Lkg 1 PLG9 214951 Conn Rect Univ 039 6p S 3row Plug Cable Lkg Seal 1 214933 Seal Wire Univ 039 3 214934 Seal Plug Univ 039 3 PLG8 147992 Conn Rect Univ 039 10p S 2row Plug ...

Page 73: ...OM 223 037 Page 67 Notes 229895 MATERIAL THICKNESS GAUGE ...

Page 74: ...OM 223 037 Page 68 Notes 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Over 80 000 trained since 1930 Start Your Professional Welding Career Now ...

Page 75: ...Induction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exceptio...

Page 76: ...d retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering...

Search results

Summary of Contents for Big Blue 400 PX

Reviews:

Related manuals for Big Blue 400 PX

Brands by name

Popular brands

Miller Electric Big Blue 400 PX, Owner'S Manual

Search results

Summary of Contents for Big Blue 400 PX

Reviews:

Related manuals for Big Blue 400 PX

Brands by name

Popular brands