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Miller Electric
Welding System
Big Blue 400P
Miller Electric Big Blue 400P User Manual
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Processes
Description
TIG (GT
A
W) Welding
Stick (SMAW
)
Welding
MIG (GMAW)
Welding
Engine Driven Welding Generator
OM-4421
215 075Q
2007
−
10
Visit our website at
www.MillerWelds.com
Flux Cored (FCA
W
) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
File:
Engine Drive
Big
Blue
400P
B
i
g B
l
u
e 5
0
0 X
(Per
kins-Power
ed)
2
Table of Contents
Default Chapter
3
Table of Contents
3
Section 1 − Safety Precautions − Read before Using
7
Symbol Usage
7
Arc Welding Hazards
7
Engine Hazards
9
Compressed Air Hazards
9
Additional Symbols for Installation, Operation, and Maintenance
10
California Proposition 65 Warnings
11
Principal Safety Standards
11
EMF Information
11
Section 2 − Consignes de Sécurité − Lire Avant Utilisation
12
Signification des Symboles
12
Dangers Relatifs Au Soudage À L'arc
12
Dangers Existant en Relation Avec Le Moteur
14
Dangers Liés À L'air Comprimé
15
Dangers Supplémentaires en Relation Avec L'installation, Le Fonctionnement Et la Maintenance
15
Proposition Californienne 65 Avertissements
17
Principales Normes de Sécurité
17
Information EMF
17
Section 3 − Definitions
18
Warning Label Definitions (for Wordless Labels)
18
Manufacturer's Rating Labels
19
Symbols and Definitions
20
Section 4 − Specifications
21
Weld, Power, and Engine Specifications
21
Dimensions, Weights, and Operating Angles
21
Volt-Ampere Curves for CC Models
22
Volt-Ampere Curves for CC/CV Models
23
Fuel Consumption
24
Duty Cycle and Overheating
24
AC Generator Power Curve
25
Optional Three-Phase Generator Curves
25
Section 5 − Installation
26
Installing Welding Generator
26
Using Lifting Eye
27
Mounting Welding Generator
28
Installing Exhaust Pipe
29
Activating the Dry Charge Battery (if Applicable)
30
Connecting the Battery
30
Engine Prestart Checks
31
Connecting to Weld Output Terminals
32
Selecting Weld Cable Sizes
33
Connecting to Remote Amperage Adjust Receptacle RC13 on CC Models
33
Connecting to Remote 14 Receptacle RC14 on CC/CV Models
34
Section 6 − Operating Welding Generator − CC Models
36
Front Panel Controls for CC Models (See Section 6-2)
36
Description of Front Panel Controls for CC Models (See Section 6-1)
37
Remote Amperage Control on CC Models (Optional)
38
Weld Control/Arc Condition Information Label
38
Section 7 − Operating Welding Generator − CC/CV Models
40
Front Panel Controls for CC/CV Models (See Section 7-2)
40
Description of Front Panel Controls for CC/CV Models (See Section 7-1)
41
Process/Contactor Switch on CC/CV Models
42
Remote Voltage/Amperage Control on CC/CV Models (Optional)
43
Section 8 − Operating Auxiliary Equipment
44
120 Volt and 240 Volt Receptacles
44
Connecting to Optional Three-Phase Generator (CC/CV Models Only)
45
Optional Generator Power Receptacles
46
Section 9 − Maintenance & Troubleshooting
47
Maintenance Label
47
Routine Maintenance
48
Checking Generator Brushes
49
Servicing Air Cleaner
50
Inspecting and Cleaning Optional Spark Arrestor Muffler
51
Adjusting Engine Speed
52
Servicing Fuel and Lubrication Systems
53
Overload Protection
54
Troubleshooting
55
Circuit Diagram for CC Welding Generator
60
Section 10 − Electrical Diagrams
60
Section 11 − Run-In Procedure
64
Wetstacking
64
Run-In Procedure Using Load Bank
65
Run-In Procedure Using Resistance Grid
66
Section 12 − Generator Power Guidelines
67
Grounding When Supplying Building Systems
68
Section 13 − Parts List
74
4
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Miller Electric Big Blue 400P Specifications
General
Brand
Miller Electric
Model
Big Blue 400P
Category
Welding System
Language
English
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