Miller Big Blue Turbo Owner'S Manual Download Page 23

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OM-4420 Page 19

5-6. Using The Optional Battery Disconnect Switch

803 454 / Ref. 803 324

Stop engine.

Battery Disconnect Switch

The battery disconnect switch dis-

connects battery voltage from the

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 using a

customer-supplied padlock.

OFF

Notes

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since 1930!

400 Trade Square East, Troy, Ohio 45373

1-800-332-9448 www.welding.org

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Welding Career Now!

Summary of Contents for Big Blue Turbo

Page 1: ...c CAC A Cutting and Gouging Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding Engine Driven Welding Generator OM 4420 212 049M 2006 12 TIG GTAW Welding Big Blue Turbo Visit our website at ww...

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: ...nsions Weights And Operating Angles 10 4 4 Stick And MIG Volt Ampere Curves 11 4 5 DC TIG Volt Ampere Curves 12 4 6 Fuel Consumption 12 4 7 Duty Cycle And Overheating 13 4 8 Generator AC Power Curve 1...

Page 4: ...1 Wetstacking 42 11 2 Run In Procedure Using Load Bank 43 11 3 Run In Procedure Using Resistance Grid 44 SECTION 12 GENERATOR POWER GUIDELINES 45 SECTION 13 SELECTING AND PREPARING A TUNGSTEN FOR DC...

Page 5: ...ch proper grounding conductor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipme...

Page 6: ...o treat them carefully CYLINDERS can explode if damaged Protect compressed gas cylinders from excessive heat mechanical shocks physical damage slag open flames sparks and arcs Install cylinders in an...

Page 7: ...fire or explosion Do not cut or gouge near flammables Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury Do not touch hot compressor or air system parts Let system cool down...

Page 8: ...Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1...

Page 9: ...rifier les connexions V rifier fr quemment le cordon d alimentation pour voir s il n est pas endom mag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une le...

Page 10: ...ement partie du proc d de soudage les manipuler avec pr caution Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvert...

Page 11: ...de toucher ou d effectuer la mainte nance LIRE LES INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil Arr ter le moteur et rel cher la pression avant d ef...

Page 12: ...rd Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com RecommendedSafe Practices for the Preparation for Welding and Cutting of Containers and Piping Ameri...

Page 13: ...Engine Oil Check Injectors Pump Check Valve Clearance Fuel Engine Coolant Temperature Positive Negative Wire Feed Welding Arc A Amperes V Volts Panel Local Remote Output Direct Current DC Alternating...

Page 14: ...m 78 8 dBA 3 3 ft 1 m from front panel 103 0 Lwa sound power 78 1 dBa at 23 ft 7 m 86 0 dBA 3 3 ft 1 m from front panel 104 5 Lwa sound power 79 6 dBa at 23 ft 7 m 91 8 dBA 3 3 ft 1 m from front panel...

Page 15: ...tput capabilities of the welding generator Curves of all other settings fall between the curves shown B MIG Mode A DC Stick Mode 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES...

Page 16: ...the curves shown 0 20 40 60 80 100 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 DC AMPERES DC VOLTS Ranges 60 450 40 330 30 220 20 110 4 6 Fuel Consumption The curve shows typical fuel us...

Page 17: ...rranty 100 Duty Cycle At 600 Amperes DUTY CYCLE WELD AMPERES 10 15 20 30 40 50 60 80 100 25 100 150 200 250 300 400 500 600 800 1000 4 8 Generator AC Power Curve 193 018 The ac power curve shows the g...

Page 18: ...OM 4420 Page 14 4 9 Manufacturing Rating Label...

Page 19: ...on 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 vehi...

Page 20: ...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 21: ...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 22: ...ecessary add electro lyte to raise to proper level Reins tall vent caps 14 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes o...

Page 23: ...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 24: ...g to pre vent air from entering the fuel system see engine maintenance label for fuel specifica tions Leave filler neck empty to allow room for expansion Engine stops if fuel level is low on units wit...

Page 25: ...and 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 min...

Page 26: ...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 3x9...

Page 27: ...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 control at max OR 115 VOLTS AC I 115 volts 10 amperes 60 H...

Page 28: ...OM 4420 Page 24 SECTION 6 OPERATING THE WELDING GENERATOR 6 1 Controls See Section 6 2 803 454 217 638 A 8 11 1 9 12 13 10 5 6 4 7 3 2...

Page 29: ...7 Battery Voltmeter Use gauge to check battery voltage and moni tor the engine charging system The meter should read about 14 volts dc when the en gine is running and about 12 volts dc when the engin...

Page 30: ...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 31: ...Min 125 A DC Max 400 A DC Adjust Optional Remote Control Set Panel Remote Switch Set Range Control Not Used In Remote Stick Mode Max 400 A DC Min 125 A DC Set Remote Process Example Combination Remot...

Page 32: ...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 33: ...utton 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 Press button to reset breaker CB3...

Page 34: ...urs FUEL WATER Section 5 7 8 6 Fuel Water Separator Fuel Level Oil Level Oil Fuel Spills Every 50 Hours Weld Terminals Every 100 Hours Section 8 3 Battery Terminals Air Cleaner Hoses Air Cleaner Eleme...

Page 35: ...OM 4420 Page 31 8 2 Engine Maintenance Label...

Page 36: ...ditional 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 cle...

Page 37: ...ut cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fireproof material Stop engine and let cool Reinstall cleanout plug Tools Needed 3 8 in 1 2 8 5 Checking Generator...

Page 38: ...ick Weld Terminals Always On 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 39: ...ace primary fuel filter Turn filter counterclockwise Remove filter Apply thin coat of fuel to gasket on new filter Fill filter with fuel Install filter and turn clock wise until tight Bleed air from f...

Page 40: ...y 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 weld output and 24 volt output...

Page 41: ...ngs 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...

Page 42: ...open see Section 8 8 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 diode capacitor board D1 C1 and the rotor Reset supplementary protectors CB12 Have Factory Autho...

Page 43: ...oil for cold weather see Section 8 2 Engine suddenly stops Check fuel level Optional low fuel shutdown stops engine if fuel level is low Check oil level Automatic shutdown system stops engine if oil...

Page 44: ...OM 4420 Page 40 SECTION 10 ELECTRICAL DIAGRAM Figure 10 1 Circuit Diagram For Welding Generator...

Page 45: ...OM 4420 Page 41 217 852 D...

Page 46: ...r specifications section in this manual to find rated voltage and current Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generatoris...

Page 47: ...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 48: ...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...

Page 49: ...enerator To Truck Or Trailer Frame S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Equipment Grounding Terminal On Front Panel 2 Groun...

Page 50: ...istive 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 12 8 3 Rating Data Rating shows volt...

Page 51: ...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 52: ...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 53: ...r Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of...

Page 54: ...f required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Connect generator with temporary or perm...

Page 55: ...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 56: ...duces 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 57: ...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 58: ...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 59: ...OM 4420 Page 55 14 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 60: ...re is common and not available unless listed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 104 105 106 107 108 109 110 112 13 114 115 116 118 120 121 113 117 Figure 15 3 111 Figure 15...

Page 61: ...33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 49 48 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 62 65 66 67 68 69 70 71 72 73 74 77 76 75 78 79 80 83 82 84 85 81 87 86 88 89 90 91 92 101 102 103 94 95...

Page 62: ...nt Safety 1 206556 Pipe Air Cleaner Intake Deutz Turbo Hose To Air Cleaner Hose 1 17 189763 Bracket Mtg Air Cleaner 1 18 206351 Upright Center Assy 1 19 189464 Seal Weather Lift Eye 1 20 209612 Lever...

Page 63: ...al Protector Battery Post Mtg 2 57 190206 Cable Bat Neg 42 In Lg 2 Awg W Clamp 375 Rng 1 58 190207 Cable Bat Pos 45 In Lg No 1 Awg W Clamp 406 Rng 1 59 203430 Bracket Battery Holddown 1 60 201183 Cove...

Page 64: ...Elbow W 047in Orifice Zinc Pld 1 97 189909 Ftg Stand Pipe Hose 250 X 9 265lg 90 Deg Zinc 1 98 189913 Ftg Stl Barbed Elbow Zinc Pld 1 99 190142 Sender Fuel Gauge 9 750 Deep Tank 1 100 189910 Ftg Stand...

Page 65: ...40 Door Access Lh 1 209236 Tab Lockout 1 209241 Mount Access Rh 1 209242 Mount Access Lh 1 189975 Hinge Door Access 180 Deg 4 155146 Sponge Nprn 060 X 1 000 Wide X 4 000 Sce 41 Close 3 When ordering a...

Page 66: ...OM 4420 Page 62 803 456 A 1 2 3 4 5 10 6 15 17 16 7 8 9 13 14 20 21 11 12 19 18 22 19 Figure 15 2 Control Box Assembly...

Page 67: ...On Make Break Open 30 Sec 12vdc 1 14 201079 Cover Control Box 1 15 217823 Label Layout Control Box 1 217815 Harness Engine Deutz Bf4m2011 includes 1 16 CB10 190374 Circuit Breaker Auto Reset 12vdc 40...

Page 68: ...13 14 15 16 36 34 35 1 11 12 23 27 32 33 Figure 15 3 Panel Front w Components Description Part No Dia Mkgs Item No Figure 15 3 Panel Front w Components Figure 15 1 Item 117 Quantity 1 217638 Plate Sc...

Page 69: ...pt 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 215347 Panel Power 1 18 601836 Nut 250 20 50h...

Page 70: ...Conduit Convoluted 1 2 In 6 35mm Mtg Hole 3 187654 Seal Wire Univ 12p S 3row 1 196602 Plug Cavity 18 30 Position Cinch Connector 7 059712 Clip Component 437 Dia Mtg Adh Back 1 024103 Blank Snap in Ny...

Page 71: ...it10mm 10 19 080389 Screw 312 18x1 00 Hexwhd 66d Stl Pld Slffmg Tap rw 8 20 083883 Washer Lock 402idx0 709odx 087t Stl Split10mm 4 21 049026 Screw M10 1 5x 25 Hex Hd pln 8 8 Pln 4 22 191579 Cover Star...

Page 72: ...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 188493...

Page 73: ...tes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL THICKNES...

Page 74: ......

Page 75: ...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...

Page 76: ...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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