Miller-electric Big Blue 400 PX User Manual

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Big Blue 400 PX
OM-229 979G
200705
Processes
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
)
File: Engine Drive
Visit our website at
www.MillerWelds.com
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Summary of Contents

Page 1 - Big Blue 400 PX

Big Blue 400 PXOM-229 979G2007−05ProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and GougingStick (SMAW) WeldingEngine Driven Welding GeneratorTIG (

Page 2 - From Miller to You

OM-229 979 Page 4HOT METAL from air arc cutting andgouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep ex

Page 3 - TABLE OF CONTENTS

OM-229 979 Page 5H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcomm

Page 4

OM-229 979 Page 6SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_2007−04freSe protéger, ainsi que toute autre personne travaillant sur l

Page 5 - Declaration of Conformity for

OM-229 979 Page 7DES PIÈCES CHAUDES peuventprovoquer des brûlures graves. Ne pas toucher à mains nues les parties chau-des. Prévoir une période de r

Page 6

OM-229 979 Page 8LES CHAMPS MAGNETIQUES peuv-ent affecter des implants médicaux. Porteur de simulateur cardiaque ou autre im-plants médicaux, rester

Page 7 - 1-2. Arc Welding Hazards

OM-229 979 Page 9L’utilisation d’un groupe autonomeà l’intérieur PEUT VOUS TUER ENQUELQUES MINUTES. Les fumées d’un groupe autonome contient dumonoxy

Page 8 - Medical Devices

OM-229 979 Page 10LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant dedémarrer ou d’arrêter le moteu

Page 9 - 1-4. Compressed Air Hazards

OM-229 979 Page 112-6. Proposition californienne 65 AvertissementsLes équipements de soudage et de coupage produisent desfumées et des gaz qui contien

Page 10

OM-229 979 Page 12SECTION 3 − DEFINITIONS3-1. Warning Label Definitions3/961 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followins

Page 11 - 1-8. EMF Information

OM-229 979 Page 133-2. Manufacturer’s Rating Label

Page 12 - UTILISATION

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

Page 13

OM-229 979 Page 143-3. Symbols And Definitions Some symbols are found only on CE products.Stop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineSt

Page 14 - LE CARBURANT MOTEUR peut prov

OM-229 979 Page 15SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated WeldingOutputMaximumOpen-Circu

Page 15

OM-229 979 Page 16DC AMPERES0 100 200 300 400 500020406080100DC VOLTS4-3. Volt-Ampere Curves222 108 / 221 800 / 217 518The volt-ampere curves show the

Page 16

OM-229 979 Page 174-4. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.217 509IDLEDC WELD AMPERES AT 100% DUTY CYCLEU.S. GAL

Page 17 - 2-8. Information EMF

OM-229 979 Page 184-6. AC Generator Power Curve220 346−BThe ac power curve shows the gen-erator power in amperes.AC AMPERES IN 110V MODEAC AMPERES IN

Page 18 - SECTION 3 − DEFINITIONS

OM-229 979 Page 19SECTION 5 − INSTALLATIONinstall3 8/06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712! Always securely fasten weld-ing generator

Page 19 - OM-229 979 Page 13

OM-229 979 Page 205-2. Mounting Welding GeneratorTools Needed:9/16 in224Welding Unit In PlaceBolting Unit In Place! Do not weld on base. Weld-ing on b

Page 20 - 3-3. Symbols And Definitions

OM-229 979 Page 215-3. Installing Exhaust Pipe1/2 inTools Needed:803 582−F / Ref. 229 747-A! Stop engine and let cool. Point exhaust pipe in desired

Page 21 - SECTION 4 − SPECIFICATIONS

OM-229 979 Page 225-4. Activating The Dry Charge Battery (If Applicable)! Always wear a face shield,rubber gloves and protectiveclothing when working

Page 22 - 222 108 / 221 800 / 217 518

OM-229 979 Page 235-6. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break

Page 23

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol

Page 24 - 4-6. AC Generator Power Curve

OM-229 979 Page 245-7. Connecting To Weld Output TerminalsTools Needed:3/4 inRef.804 630-A / Ref. 229 747-A / 803 778-A645Do not placeanything between

Page 25 - SECTION 5 − INSTALLATION

OM-229 979 Page 255-8. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Le

Page 26 - ! Do not use flexible mounts

OM-229 979 Page 265-9. Connecting To Remote 14 Receptacle RC14Socket* Socket Information24 VOLTS ACA 24 volts ac. Protected by sup-plementary protecto

Page 27 - Work like a Pro!

OM-229 979 Page 27SECTION 6 − OPERATING THE WELDING GENERATOR6-1. Front Panel Controls (See Section 6-2)229 747-B / 804 009-C1 2546789103Stop

Page 28

OM-229 979 Page 286-2. Description Of Front Panel Controls (See Section 6-1)Engine Starting Controls1 Preheat SwitchUse switch to energize starting ai

Page 29 - 5-6. Engine Prestart Checks

OM-229 979 Page 296-3. Process/Contactor Switch1 Process/Contactor Switch! Weld output terminals are ener-gized when Process/Contactorswitch is in a W

Page 30 - ! Stop engine

OM-229 979 Page 306-4. Remote Voltage/Amperage Control1 Remote 14 Receptacle RC14Connect optional remote control to RC14 (seeSection 5-9). When a rem

Page 31 - ! Do not use worn, dam

OM-229 979 Page 31SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. 110 Volt ReceptaclesRef. 229 747-A1 110 V 32 A AC Receptacle RC112 110 V 16A AC Recept

Page 32

OM-229 979 Page 32SECTION 8 − MAINTENANCE & TROUBLESHOOTING8-1. Maintenance Label

Page 33 - 229 747-B / 804 009-C

OM-229 979 Page 338-2. Routine Maintenance! Stop engine before maintaining. See Engine Manual and Maintenance Labelfor important start-up, service,

Page 34

TABLE OF CONTENTS8-6. Inspecting And Cleaning Spark Arrestor Muffler 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 35 - 6-3. Process/Contactor Switch

OM-229 979 Page 348-3. Perkins Customer AssistanceServiceWhen a problem arises concerning the op-eration or service of the engine, the prob-lem will n

Page 36

OM-229 979 Page 358-5. Servicing Air Cleaner! Stop engine.NOTICE − Do not run engine without aircleaner or with dirty element. Enginedamage caused by

Page 37 - 7-1. 110 Volt Receptacles

OM-229 979 Page 368-6. Inspecting And Cleaning Spark Arrestor Muffler803 582-F / Ref. 229 747-A! Stop engine and let cool.1 Spark Arrestor Muffler2 Cl

Page 38 - 8-1. Maintenance Label

OM-229 979 Page 378-8. Adjusting Engine Speed On Standard Models804 009−C312RPM (Hz)Engine Speed(No Load)Weld/Power1850 (61.7)Maximum! Stop engine and

Page 39 - 8-2. Routine Maintenance

OM-229 979 Page 388-9. Adjusting Engine Speed On Models With Automatic Idle (Optional)803 563-G1880 rpm max(62.6 Hz)1500 rpm(50 Hz)Engine Speed(No Loa

Page 40 - ! Stop engine and let cool

OM-229 979 Page 398-10. Servicing Fuel And Lubrication SystemsRef 229 747-A / 804 009−C! Stop engine and let cool.! After servicing, start engineand c

Page 41 - 8-5. Servicing Air Cleaner

OM-229 979 Page 408-11. Overload ProtectionRef. 229 747-A / 803 566-E / 804 630-A! Stop engine. When a circuit breaker, supple-mentary protector, or

Page 42

OM-229 979 Page 418-12. Optional Voltmeter/Ammeter Help DisplaysUse the Voltmeter/Ammeter helpdisplays to diagnose and correctfault conditions. When

Page 43

OM-229 979 Page 428-13. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-12).A. We

Page 44 -  Weld/power speed adjust

OM-229 979 Page 43Trouble RemedyReset supplementary protector CB3 (see Section 8-11).Check Voltmeter/Ammeter help displays (see Section 8-12).Have Fac

Page 45

dec_rot_1/07Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating labe

Page 46 - 8-11. Overload Protection

OM-229 979 Page 44Trouble RemedyBattery discharges between uses. Turn Engine Control switch off when unit is not running.Clean top of battery with bak

Page 47 - Ref. 804 630-A

OM-229 979 Page 45Notes229895MATERIAL THICKNESS GAUGE

Page 48 - 8-13. Troubleshooting

OM-229 979 Page 46SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator

Page 49 - C. Engine

OM-229 979 Page 47229 746-D

Page 50 - Trouble Remedy

OM-229 979 Page 48SECTION 10 − RUN-IN PROCEDURErun_in1 2007−0410-1. Wetstacking1 Welding GeneratorRun diesel engines near rated volt-age and current d

Page 51 - MATERIAL THICKNESS GAUGE

OM-229 979 Page 4910-2. Run-In Procedure Using Load BankS-0683! Stop engine.! Do not touch hot exhaustpipe, engine parts, or loadbank/grid.! Keep exha

Page 52 - OM-229 979 Page 46

OM-229 979 Page 5010-3. Run-In Procedure Using Resistance GridS-0684! Stop engine.! Do not touch hot exhaustpipe, engine parts, or loadbank/grid.! Kee

Page 53 - OM-229 979 Page 47

OM-229 979 Page 51SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding ge

Page 54 - SECTION 10 − RUN-IN PROCEDURE

OM-229 979 Page 5211-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insul

Page 55 - ! Keep exhaust and pipe away

OM-229 979 Page 5311-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 80

Page 56

dec_rotsound_6/05Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating

Page 57 -  Electrically bond generator

OM-229 979 Page 5411-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 350

Page 58 - ! Also see AWS Safety &

OM-229 979 Page 5511-8. Power Required To Start MotorSingle-Phase Induction Motor Starting RequirementsMotor StartCodeG H J K L M N PKVA/HP 6.3 7.1 8

Page 59

OM-229 979 Page 5611-10. Typical Connections To Supply Standby PowerTransfer SwitchEssentialLoadsFusedDisconnectSwitch(If Required) UtilityElectricalS

Page 60

OM-229 979 Page 5711-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt LoadsIf unit does not have GFCI receptacles, u

Page 61 - Ref. ST-800 396-A / S-0625

OM-229 979 Page 58SECTION 12 − PARTS LIST Hardware is common and notavailable unless listed.Wiring harnesses are listed atthe end of parts section.2−

Page 62 -  Customer-supplied equipment

OM-229 979 Page 59804 632-A / Ref. 803 683-D557375747677787972−Fig.12−47069686766645658575960636261363738394041444549505152465354554847463334353231302

Page 63

OM-229 979 Page 60DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 HD1 168829 Transducer, Current 1000a Module Max Open Loop 1.

Page 64 - SECTION 12 − PARTS LIST

OM-229 979 Page 6153 189975 Hinge, Door Access 180 Deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 65 - 804 632-A / Ref. 803 683-D

OM-229 979 Page 62DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity213600 Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln 1.

Page 66 - OM-229 979 Page 60

OM-229 979 Page 63 Hardware is common and notavailable unless listed.Wiring harnesses are listed atthe end of parts section.804 633-A1234563635789101

Page 67 - OM-229 979 Page 61

OM-229 979 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom_2007−04Protect yourself and others from injury — read and follow these precauti

Page 68 - OM-229 979 Page 62

OM-229 979 Page 64DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Panel, Front w/Components (Continued)Quantity16 S1 212436 Switch, Ignition 4 Position

Page 69 -  Hardware is common and not

OM-229 979 Page 65 Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.803 689-D12345678910131211

Page 70 - OM-229 979 Page 64

OM-229 979 Page 66803 686-A Hardware is common and notavailable unless listed.Wiring harnesses are listed atthe end of parts section.2314567891011121

Page 71

OM-229 979 Page 67803 685-A Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.12364598107Figure

Page 72

OM-229 979 Page 68 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purc

Page 73

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2007−01Your distributor also givesyou ...ServiceYou always get the

Page 74 - OM-229 979 Page 68

PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914

Page 75 - Effective January 1, 2007

OM-229 979 Page 2Welding produces fumes and gases. Breathing thesefumes and gases can be hazardous to your health.FUMES AND GASES can be hazardous. K

Page 76 - Owner’s Record

OM-229 979 Page 31-3. Engine HazardsBATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, andprotective clothing when working on a b

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