Miller Electric Big Blue Air Pak Owner'S Manual Download Page 82

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OM-4409 Page 78

18-2. Torch Movement During Welding

ST-162 002-B

Tungsten Without Filler Rod

Tungsten With Filler Rod

Form pool

Tilt torch

Move torch to front

of pool. Repeat process.

Welding direction

Form pool

Tilt torch

Add filler metal

Move torch to front

of pool. Repeat process.

Remove rod

Welding direction

Summary of Contents for Big Blue Air Pak

Page 1: ...ck SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding Engine Driven Welding Generator And Air Compressor OM 4409 206 941V 2007 05 TIG GTAW Welding With Optional Equipment Battery Charging Big Blue...

Page 2: ...tinue 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...

Page 3: ...ications 13 4 3 Sound Level Table 13 4 4 Dimensions Weights And Operating Angles 14 4 5 Stick And MIG Volt Ampere Curves 15 4 6 TIG Volt Ampere Curves 16 4 7 Fuel Consumption 17 4 8 Duty Cycle And Ove...

Page 4: ...ce 52 10 3 Servicing Compressor Air Cleaner 53 10 4 Compressor Overload Protection 54 10 5 Servicing Air Compressor 55 10 6 Adjusting Compressor Air Pressure 56 SECTION 11 TROUBLESHOOTING 57 11 1 Trou...

Page 5: ...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 man...

Page 6: ...ing 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 o...

Page 7: ...s 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...

Page 8: ...ge 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 t...

Page 9: ...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 Assoc...

Page 10: ...l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structure...

Page 11: ...Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les t...

Page 12: ...r les batteries D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion Arr ter le moteur avant de v rifier le niveau...

Page 13: ...e changer ou de rajouter des l ments 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 p...

Page 14: ...INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil N utiliser que les pi ces de rechange recom mand es par le constructeur Effectuer la maintenance et le s...

Page 15: ...onal Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standa...

Page 16: ...ump Check Valve Clearance Fuel Engine Coolant Temperature Hourmeter HM Air Pressure Temperature Air Compressor Positive Negative Wire Feed Welding Arc A Amperes V Volts Panel Local Remote Output Direc...

Page 17: ...ompressor Model And Type Air Output At Effective Working Pressure Factory Pressure Setting Safety Relief Valve Rating Air Compressor Oil Capacity Ingersoll Rand CE55 G Rotary Screw 60 scfm 1 7 m3 min...

Page 18: ...tip A 69 1 2 in 1765 mm tip B 55 7 8 in 1419 mm C 46 3 8 in 1178 A D 11 in 279 mm B C E 27 1 2 in 699 mm F 1 in 25 mm G 29 13 16 in 757 mm H 30 H 9 16 in 14 mm Dia 4 Holes Front Panel End D 20 30 With...

Page 19: ...Curves of all other settings fall between the curves shown C MIG Mode A DC Stick Mode B AC Stick Mode Optional 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES DC VOLTS Ranges...

Page 20: ...put capabilities of the welding generator Curves of all other settings fall between the curves shown A DC TIG Mode B AC TIG Mode Optional 0 20 40 60 80 100 0 50 100 150 200 250 300 350 400 450 500 550...

Page 21: ...100 DUTY CYCLE US Gal Hr IDLE w Air Output Continuous Welding 4 8 Duty Cycle And Overheating 202 356 Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating NOTICE...

Page 22: ...n amperes available at the 120 and 240 volt receptacles 0 50 100 150 200 250 300 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE AC VOLTS 0 25 50 75 100 150 125 0 10 20 30 40 50 60 AC AMPERES IN 120V MODE...

Page 23: ...gle phase 120 240 volt re ceptacle or three phase 240 volt terminals A 12 kVA kW Single Phase AC Output No Weld Load B 20 kVA kW Three Phase AC Output No Weld Load 180 190 200 210 220 230 240 250 260...

Page 24: ...60 70 80 90 100 CUBIC FEET PER MINUTE CFM POUNDS PER SQUARE INCH PSI Idle 4 12 Optional Battery Charging Output Curve 210 269 The battery charging curves show the charging amperage and voltage output...

Page 25: ...OM 4409 Page 21 4 13 Manufacturing Rating Label...

Page 26: ...ction 5 2 for mounting in formation Grounding 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal v...

Page 27: ...ackets 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 Bo...

Page 28: ...2 Double Flanged Elbow 3 Nut 4 Flat Washer 5 Mount 6 Bracket 7 Screw 8 Single Flanged Elbow 9 Rain Cap 10 Clamp Loosely assemble components as shown Mount the muffler with the clean out plug to the ou...

Page 29: ...cessary add electro lyte to raise to proper level Reins tall vent caps 4 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes or...

Page 30: ...he circuit When the switch is turned Off the front panel controls do not work To run unit turn switch to On posi tion To prevent unit from running turn switch to Off position The switch may be locked...

Page 31: ...ns Leave filler neck empty to allow room for expansion Engine stops if fuel level is low on units with low fuel shutdown option Do not run out of fuel or air may enter fuel system and cause starting p...

Page 32: ...work cable to Negative terminal on right For Stick and TIG Direct Current Elec trode Negative DCEN connect elec trode holder cable to Negative terminal on right and work cable to Positive ter minal o...

Page 33: ...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...

Page 34: ...e 0 to 10 volts dc in TIG mode REMOTE OUTPUT D Remote control circuit common OUTPUT CONTROL E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust contr...

Page 35: ...the engine is running and the front panel Compressor switch is moved to the On position see Section 6 1 Run engine at weld power speed for maxi mum air compressor output Compressor output is reduced...

Page 36: ...OM 4409 Page 32 SECTION 6 OPERATING THE WELDING GENERATOR 6 1 Controls See Section 6 2 803 229 217 356 A 13 17 2 1 11 15 16 12 6 5 7 4 8 3 14 9 18 10...

Page 37: ...Use all five ranges for Stick welding and the lowest four ranges for TIG welding Read the upper set of numbers at each range for Stick welding and the lower set at each range for TIG welding Use the...

Page 38: ...uit provides addition al amperage during low voltage short arc length conditions to prevent stick ing electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG positions The engine...

Page 39: ...C Max 400 A DC Adjust Optional Remote Control Set Panel Remote Switch Set Range Control Not Used In Remote On Off Switch Required Stick Mode Max 400 A DC Min 125 A DC Set Remote Process Example Combin...

Page 40: ...test button to verify GFCI is working properly 3 Supplementary Protector CB1 4 Supplementary Protector CB2 CB1 protects RC1 and the genera tor winding from overload If CB1 opens RC1 and GFCI1 do not w...

Page 41: ...Circuit Grounding Lead 7 Lead 90 Neutral 8 Isolated Neutral Terminal 9 Jumper Lead 42 10 Grounding Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neutral to...

Page 42: ...n to verify GFCI is working properly 5 Supplementary Protector CB2 6 Supplementary Protector CB3 CB2 protects GFCI1 from overload If CB2 opens GFCI1 does not work Place button to reset breaker CB3 pro...

Page 43: ...eing charged When done charging stop engine or set Pro cess Contactor switch to any Remote On Off Switch Required position Move Output Selec tor switch to AC Weld or DC Weld position 803 231 A 210 149...

Page 44: ...arged 1 Battery 2 Battery Charging Cables For battery charging use less than 20 feet 6 1 m of AWG 1 or larger cable For jump starting use less than 20 feet 6 1 m of AWG 2 0 or larger cable 3 Terminal...

Page 45: ...n This battery charging procedure uses the front panel controls to turn charging output on and off Charge 10 minutes Check Battery Voltage Continue Charging If Necessary Set Process Contactor Switch T...

Page 46: ...Charge battery for 10 minutes before jump starting battery Stop Engine Set Ampere Range Switch To 300 Max Position NOTICE Do not switch under load Press Close Remote Momentary On Switch While Crankin...

Page 47: ...OM 4409 Page 43 SECTION 9 ENGINE GENERATOR MAINTENANCE 9 1 Engine Maintenance Label...

Page 48: ...erence Every 8 Hours FUEL WATER Section 5 7 9 6 Fuel Water Separator Fuel Level Oil Level Oil Fuel Spills Every 50 Hours Weld Terminals Every 100 Hours Section 9 4 Battery Terminals Air Cleaner Hoses...

Page 49: ...maged or if brush material is at or near minimum length 1 Damaged Brushes New Length 1 1 4 in 32 mm Minimum Length 5 8 in 16 mm Replace Notes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 0...

Page 50: ...additional engine protection Never clean a safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before...

Page 51: ...Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole Start engine and run at idle speed to blow out cleanout hole If nothing blows out of hole briefly cover en...

Page 52: ...ld Terminals Always On Stick position 1 Throttle Rod 2 Locknut Loosen locknuts Place engine control switch in Run Idle position Wait 15 seconds for throttle sole noid to energize and lower engine spee...

Page 53: ...to metal container Close petcock when water free fuel flows To replace primary fuel filter Turn filter counterclockwise Remove filter Apply thin coat of fuel to gasket on new filter Fill filter with f...

Page 54: ...gth conditions CB4 automatically resets when the fault is corrected CB5 protects the 24 volt ac output to re mote receptacle RC14 and 24 volt out put to field current regulator board PC1 If CB5 opens...

Page 55: ...or The air compressor warranty will be reduced to 2 years if non Ingersoll Rand oil and filters are used The air compressor normally requires service at the intervals listed in the maintenance schedul...

Page 56: ...essor more often if used in severe conditions Recycle air compressor fluids Check Change Clean Replace To be done by Factory Authorized Service Agent Reference Every 8 Hours Section 5 7 Spills Oil Lev...

Page 57: ...commend instal ling an optional safety element to pro vide additional air compressor protection Never clean a safety ele ment Replace the safety element af ter servicing the primary element three time...

Page 58: ...s a more serious problem exists Contact Factory Authorized Service Agent See Section 9 8 for engine genera tor overload protection 1 Circuit Breaker CB15 Circuit breaker CB15 protects the air compress...

Page 59: ...through hole in base Remove compressor oil fill cap Re move cap from oil drain hose and drain oil into a suitable container Reinstall oil drain hose cap Tighten cap with wrench Remove filter by turnin...

Page 60: ...s 1 Screw Loosen jam nut securing screw Turn screw clockwise increase pressure or counterclockwise decrease until pressure is 125 psi 862 kPa Maximum weld output is reduced if compressor air pressure...

Page 61: ...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 exc...

Page 62: ...brushes and slip rings and field excitation circuit High output at generator power receptacles Check engine weld power speed and adjust if necessary see Section 9 6 Have Factory Authorized Service Ag...

Page 63: ...ctory Authorized Service Agent check time delay relay TD1 and control relay CR5 Engine hard to start in cold weather Use starting aid switch see Section 6 1 If Starting Aid switch does not work have F...

Page 64: ...ssor air pressure see Section 10 6 Check air compressor air cleaner see Section 10 3 Have Factory Authorized Service Agent check compressor for rated output High air pressure Adjust compressor air pre...

Page 65: ...OM 4409 Page 61 SECTION 12 AIR COMPRESSOR DIAGRAM 209 059 A Figure 12 1 Circuit Diagram For Air Compressor...

Page 66: ...OM 4409 Page 62 SECTION 13 CIRCUIT DIAGRAM Figure 13 1 Circuit Diagram For Welding Generator...

Page 67: ...OM 4409 Page 63 221 915 C...

Page 68: ...gs 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...

Page 69: ...erator 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...

Page 70: ...ors 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...

Page 71: ...6 19 4 34 5 30 0 156 0 632 1 40 2 52 5 6 10 0 22 5 40 0 35 0 173 0 71 1 56 2 80 6 2 11 2 25 0 44 7 40 0 19 0 77 1 71 3 07 6 8 12 3 27 3 49 1 45 0 208 0 843 1 9 3 36 7 6 13 4 30 3 53 8 50 0 225 9 14 2...

Page 72: ...r Medium 3 6 6 0 8 4 24 Riveting Hammer Horizontal Grinder 2 3 0 5 0 7 0 20 Light 2 25 3 75 5 25 15 Horizontal Grinder 4 9 0 15 0 21 0 60 Riveting Hammer Heavy 4 5 7 5 10 5 30 Horizontal Grinder 6 9 0...

Page 73: ...ctric 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 Groun...

Page 74: ...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 r...

Page 75: ...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 M...

Page 76: ...P 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...

Page 77: ...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 Volt...

Page 78: ...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...

Page 79: ...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 GFC...

Page 80: ...oduces dust and flying sparks which can cause injury and start fires Use local exhaust forced ventilation at the grinder or wear an approved respirator Read MSDS for safety infor mation Consider using...

Page 81: ...flam mables away 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4 Filler Rod If Applicable 5 Gas Cup 6 Tungsten Electrode Select an...

Page 82: ...02 B Tungsten Without Filler Rod Tungsten With Filler Rod Form pool Tilt torch Move torch to front of pool Repeat process 75 75 Welding direction Form pool Tilt torch Add filler metal Move torch to fr...

Page 83: ...OM 4409 Page 79 18 3 Positioning Torch Tungsten For Various Weld Joints ST 162 003 S 0792 70 70 90 20 20 10 20 70 40 30 20 70 90 20 Butt Weld And Stringer Bead T Joint Lap Joint Corner Joint...

Page 84: ...less listed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 123 124 125 126 127 128 129 130 131 Figure 19 2 132 133 15 134 135 136 137 138 139 140 141 142 143 144 Figure 19 3 2...

Page 85: ...0 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 74 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111...

Page 86: ...se 1 19 189763 Bracket Mtg Air Cleaner 1 20 206351 Upright Center Assy 1 21 189464 Seal Weather Lift Eye 1 22 197613 Air Cleaner Intake 5 250 In Compressor includes 1 23 197675 Dust Ejector Air Cleane...

Page 87: ...g 1 60 209621 Ftg Stl Adapter 3 4 Sae 3 4 Jic 1 61 207269 Guard Fan LH 1 62 206749 Shroud Fan Air Pak 1 63 206558 Cooler Oil Engine Compressor 1 64 209623 Ftg Brs Adapter Long 3 4 Sae 3 4 Jic 1 65 201...

Page 88: ...1 089800 Nut 250 20 44hex 22h Stl Pld 58d Flange Defor 1 108941 Screw 250 20x1 00 Hexwhd 61d Gr5 Pld 1 156733 Nut 250 28 44hex 13h Stl Pld Sem Cone Wshr 51d 1 102 209090 Bracket Stiffener Panel 2 103...

Page 89: ...53 Bracket Mtg Box Fcr 1 148 PC1 207397 Module Field Current Regulator 1 149 085963 Spring Ext 375 Od X 041 Wire X 2 000 ForSafety Latch 1 150 105734 Pipe Muffler Extension Elbow 1 750 OD 1 151 233088...

Page 90: ...2 9 CR8 197325 Relay Encl 12vdc Spst 70a 4pin Flange Mtg 1 10 CB15 083432 Supplementary Protector Man Reset 1p 10a 250vac Frict 1 11 CB8 139266 Supplementary Protector Man Reset 1p 15a 250vac Frict Ai...

Page 91: ...l See Figure 19 3 1 211292 Conn Body 5 Terminal For Ignition Switch S1 1 211293 Conn Pack Terminal Position Assurance Lock 1 150316 Conn Rect Univ 039 6p S 3row Plug Cable Lkg 5 S10 206624 Switch Tgl...

Page 92: ...36 54 803 326 A Figure 19 3 Panel Front w Components Description Part No Dia Mkgs Item No Figure 19 3 Panel Front w Components Figure 19 1 Item 144 Quantity 1 217356 Plate Screened Ident Control Rati...

Page 93: ...FCI1 151981 Rcpt Str Dx Grd 2p3w 15 20a 125v 5 20r Gfi 1 16 RC1 147632 Rcpt Tw Lk Grd 2p3w 30a 250v L6 30r 1 010146 Clamp Nyl 625 Clamp Dia X 500 Wide 203 Mtg Hole 2 17 RC5 182954 Rcpt Str 3p4w 50a 12...

Page 94: ...Knob Pointer 875 Dia X 250 Id W Set Screwsplstc 1 57 189161 Handle Switch Range 1 58 010647 Pin Spring Cs 156 X 1 250 1 59 097924 Knob Pointer 1 625 Dia X 250 Id W Set Screwsplstc 1 072590 Lock Shaft...

Page 95: ...Can Cause Serious 1 8 190197 Guard Generator Wire Mesh 1 9 172674 Spring Ext 240 Od X 041 Wire X 3 500 Pld 2 10 039207 Baffle Air Gen 1 11 ROTOR 212997 Rotor Generator Includes 1 12 024617 Ring Rtng E...

Page 96: ...500 X 1 250 Grd Ay 3 29 188560 Clip Spring 3 30 189142 Brushholder Assy Generator 1 31 602242 Washer Flat 375idx0 875odx 083t Stl Pld 2 32 602211 Washer Lock 318idx0 586odx 078t Stl Pld Split 312 2 33...

Page 97: ...Ac 1 2 188517 Bus Bar Conn Bd 3 3 188135 Enclosure Rectifier 2 4 134201 Stand off Support Pc Card 312 375w Post lock 43 3 5 PC3 215755 Circuit Card Assy Protection 1 6 188136 Insulator Heatsink 8 7 18...

Page 98: ...1 2 3 4 5 6 7 8 9 10 11 12 13 9 14 11 15 16 17 18 19 20 22 23 24 25 26 27 4 29 31 32 33 34 70 69 68 35 37 38 36 39 40 42 62 63 64 65 66 61 28 60 59 56 55 43 44 45 46 47 48 49 54 50 67 58 53 57 41 6 7...

Page 99: ...psi 1 25 209754 Ftg Pipe Stl Elbow M 45dg 3 4 X Npt jic 45dg 1 26 214685 Hose Assy Air W Fittings 3 4 X 21 750 Lg 1 27 209787 Ftg Pipe Stl Nipple Close 3 4 Npt 2 28 209621 Fitting Stl Adapter 3 4 SAE...

Page 100: ...686 Ftg Pipe Stl Elbow 90dg 3 4bspt M X 3 4 Jic M 1 72 210023 Filter Separator Assembly includes 1 73 206747 Separator Oil Air Filter 1 74 208029 Bracket Mtg Filter Base 1 75 209646 Tubing Ssstl 312 O...

Page 101: ...nduction 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...

Page 102: ...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...

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