Gebruiksaanwijzing /service van het product Big Blue 400 PX van de fabrikant Miller Electric
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Big Blue 400 PX OM -223 037M 2007 − 11 Pro cesses Descrip tio n Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMAW ) Welding Engine Driven Welding Generator TIG (GT A W) W elding MIG (GMAW) Welding Flux Cored (FCA W ) W elding ) (50/60 Hz) V isit our website at www.
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Routine Maintenance 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
dec_rot_1/07 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W .
dec_rotsound2007_10 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Manufacturer : European Contact: Notified Body: Miller Electric Mg. Co. Mr .
OM-223 037 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury .
OM-223 037 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.
OM-223 037 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can BLIND. Always wear a face shield, rubber gloves, and protective clothing when working on a battery . Stop engine before disconnecting or connect- ing battery cables or servicing battery .
OM-223 037 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion. Do not cut or gouge near flammables. W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury . Do not touch hot compressor or air system parts.
OM-223 037 Page 5 H. F . RADIA TION can cause interference. High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation.
OM-223 037 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
OM-223 037 Page 7 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. Ne pas toucher à mains nues les parties chau - des. Prévoir une période de refroidissement avant d e travailler à l’équipement.
OM-223 037 Page 8 LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux. Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance.
OM-223 037 Page 9 L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore. JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.
OM-223 037 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. Arrêter ou déconnecter l’équipement avant d e démarrer ou d ’a rrêter le moteur . Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager le moteur électrique à cause d’une tension et d’une fré - quence trop faibles.
OM-223 037 Page 1 1 2-6. P r oposition californienne 65 A vertissem ents Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers.
OM-223 037 Page 12 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muf fler . 2 Read Owner ’s Manual. Read labels on unit. 3 Use Diesel Fuel only , and fill fuel tank.
OM-223 037 Page 13 3-2. Manufacturer ’ s Rating Label 223 081-A / Ref 804 068-E.
OM-223 037 Page 14 3-3. Symbols And Definitions Some symbols are found only on CE products. Stop Engine Fast (Run, W eld/ Power) Slow (Idle) Start Engine Starting Aid (Preheat) Battery (Engine) En.
OM-223 037 Page 15 SECTION 4 − SPECIFICA TIONS 4-1. W eld And Power Specifications W elding Mode W eld Output Range At 60 Hz (1800 rpm) W eld Output Range At 50 Hz (1500 rpm) Rated W elding Output A.
OM-223 037 Page 16 4-4. V olt-Ampere Curves − 50 Hz Operation 223 186-A / 223 187-A / 223 188-A The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown.
OM-223 037 Page 17 4-5. V olt-Ampere Curves − 60 Hz Operation 217 517 / 217 516 / 217 518 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown.
OM-223 037 Page 18 4-6. Fuel Consumption The curve shows typical fuel use under weld or power loads. 217 509 ID L E DC WELD AMPERES A T 100% DUTY CYCLE − 60 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.
OM-223 037 Page 19 4-8. Duty Cycle And Overheating − 60 Hz Operation 217 515 10 15 20 25 30 40 50 60 80 100 CC CV 1000 800 600 500 400 300 250 200 150 100 WELD AMPERES % DUTY CYCLE 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.
OM-223 037 Page 20 SECTION 5 − INST ALLA TION install3 2007 − 04 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 ! Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.
OM-223 037 Page 21 5-2. Mounting Welding Generator T ools Needed: 9/16 in 2 2 4 W elding Unit In Place Bolting Unit In Place ! Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.
OM-223 037 Page 22 5-3. Installing Exhaust Pipe 1/2 in T ools 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 W or k l i ke a P r o ! Pros wel d and cut safel y .
OM-223 037 Page 23 5-4. Activating The Dry Charge Battery (If Applicable) ! Always wear a face shield, rubber gloves and protective clothing when working on a battery . Remove battery from unit. 5 V ent Caps 6 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 7 W ell Fill each cell with electrolyte to bottom of well (maximum).
OM-223 037 Page 24 5-6. Engine Prestart Checks Check all engine fluids daily . Th e engine will not run if engine access door is open or Emergency Stop switch has been pressed (see Section 6-1). Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil.
OM-223 037 Page 25 5-7. Connecting T o Weld Output T erminals T ools Needed: 3/4 in Ref. 804 068 / 803 778 / 222 875-A 13 2 ! Stop engine. 1 Work ( − ) Weld Output T erminal 2 CV (Wire) Weld Output .
OM-223 037 Page 26 5-8. Selecting Weld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals ! Stop engine before connecting to weld output terminals.
OM-223 037 Page 27 5-9. Connecting T o Remote 14 Receptacle RC14 Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by sup- plementary protector CB8. 24 VOL TS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG mode; 0 to +10 volts dc in Stick or TIG mode.
OM-223 037 Page 28 SECTION 6 − OPERA TING WELDING GENERA TOR 6-1. Front Panel Controls (See Section 6-2 ) 218 379 − A / Ref 804 068 / 804 009 − A 1 27 6 8 9 10 1 1 12 4 Stop 3 5.
OM-223 037 Page 29 6-2. Description Of Front Panel Controls (See Section 6-1 ) Engine Controls The engine will not run if engine access door is open or Emergency Stop switch has been pressed. 1 Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing).
OM-223 037 Page 30 6-3. Process/Contactor Switch 1 Process/Contactor Switch ! W eld output terminals are ener- gized when Process/Contactor switch is in a Weld T erminals Al- ways On position and the engine is running. Use switch to select weld process and weld output on/of f control (see table be- low).
OM-223 037 Page 31 6-4. Remote V oltage/Amperage Control 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-9). When a remote control is connected to the Remote receptacle, the Auto Sense Re- mote feature automatically switches volt- age/amperage control to the remote con- trol.
OM-223 037 Page 32 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. 1 10 V olt Receptacles 222 975 1 1 10 V 32 A AC Receptacle RC1 1 2 1 10 V 16A AC Receptacle RC12 3 1 10 V 16 A AC Receptacle RC13 Receptacles supply 50 Hz single-phase power with Engine Speed switch in 50 Hz/20-300A (1500 rpm) position (see Sec- tion 6-1).
OM-223 037 Page 33 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance The engine will not run if engine access door is open or Emergency Stop switch has been pressed (see Section 6-1). ! Stop engine before maintaining. S ee Engine Manual and Maintenance Label for important start-up, service, and storage information.
OM-223 037 Page 34 8-2. Maintenance Label.
OM-223 037 Page 35 8-3. Perkins Customer Assistance Service When a problem arises concerning the op- eration or service of the engine, the prob- le m will normally be managed by the dealer in your area. Y our satisfaction is a primary concern to Perkins and to Perkins dealers.
OM-223 037 Page 36 8-5. Servicing Air Cleaner ! Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty . The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each cleaning.
OM-223 037 Page 37 8-6. Inspecting And Cleaning Spark Arrestor Muffler 803 582 / Ref. 222 875 ! Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole.
OM-223 037 Page 38 8-8. Servicing Fuel And Lubrication Systems Ref 222 875 / 804 009 − A ! Stop engine and let cool. ! After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary , and wipe up spilled fuel.
OM-223 037 Page 39 8-9. Overload Protection Ref. 222 875-A / 803 566 / 804 068 ! Stop engine. When a supplementary protec- tor , circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent.
OM-223 037 Page 40 8-10. Optional V oltmeter/Ammeter Help Displays Use the V oltmeter/Ammeter help displays to diagnose and correct fault conditions. When a help code is displayed normally weld output has stopped but generator power output may be okay .
OM-223 037 Page 41 8-1 1. T roubleshooting Also see V oltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10 ). Engine speed is controlled by an electronic governor and throttle actuator. Governor adjustment should only be done by a Factor y Authorized Service Agent.
OM-223 037 Page 42 T rouble Remedy Check fuse F1, and replace if open (see Section 8 - 9). Have Factory Authorized Service Agent check vol- tage regulator module PC3. Reset supplementary protector CB3 (see Section 8-9). Check V oltmeter/Ammeter help displays (see Section 8-10 ).
OM-223 037 Page 43 T rouble Remedy Engine suddenly stops. Close engine access door . Engine access door switch LS1 prevents engine from starting or running if door is open Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high (see Section 5-6).
OM-223 037 Page 44 SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator.
OM-223 037 Page 45 222 966--C.
OM-223 037 Page 46 SECTION 10 − RUN-IN PROCEDURE run_in1 2007 − 04 10-1. W etstacking 1 W elding Generator Ru n diesel engines near rated volt- ag e and current during run-in period to properly seat piston rings and prevent wetstacking. See name- plate, rating label, or specifications section in this manual to find rated voltage and current.
OM-223 037 Page 47 10-2. Run-In Procedure Using Load Bank S-0683 ! Stop engine. ! Do not touch hot exhaust pipe, engine parts, or load bank/grid. ! Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur .
OM-223 037 Page 48 10-3. Run-In Procedure Using Resistance Grid S-0684 ! Stop engine. ! Do not touch hot exhaust pipe, engine parts, or load bank/grid. ! Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur .
OM-223 037 Page 49 SECTION 1 1 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 1 1-1. Selecting Equipment gen_pwr 2007 − 04 − Ref.
OM-223 037 Page 50 1 1-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire.
OM-223 037 Page 51 1 1-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 H.
OM-223 037 Page 52 1 1-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw .
OM-223 037 Page 53 1 1-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kVA/HP .
OM-223 037 Page 54 1 1-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices.
OM-223 037 Page 55 1 1-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
OM-223 037 Page 56 SECTION 12 − P ARTS LIST Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 109 − Fig.12 − 3 1 11 0 − 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.
OM-223 037 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 11 2 48 41 25 42 Fig.
OM-223 037 Page 58 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 1 +213488 Panel, Engine Side 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-223 037 Page 59 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 48 217387 Baffle, Fan 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-223 037 Page 60 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 85 213668 Bracket, Mtg Unit 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-223 037 Page 61 Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 804 070-B 1 2 3 4 5 6 41 40 7 8 9 10 11 12 13 14 15 16 17 18 19 35 36 37 38 39 33 34 28 20 21 22 29 30 31 23 42 43 24 25 26 27 32 Figure 12-2.
OM-223 037 Page 62 Description Part No. Dia. Mkgs. Item No. Figure 12-2. Panel, Front w/Components (Continued) Quantity 16 S1 212436 Switch, Ignition 4 Position (Includes Knob) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-223 037 Page 63 Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 804 071-B 1 2 4 6 7 9 10 11 8 3 12 13 5 Figure 12-3. Control Panel Description Part No. Dia. Mkgs. Item No. Figure 12-3.
OM-223 037 Page 64 803 686-B Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. Figure 12-4. Generator Description Part No. Dia. Mkgs. Item No. Figure 12-4. Generator (Figure 12-1 Item 73) Quantity 1 ROTOR 212474 Rotor , Generator 4 Pole (Includes) 1 .
OM-223 037 Page 65 803 685-A Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 1 2 3 6 4 5 9 8 10 7 Figure 12-5. Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 12-5. Rectifier Assembly (Figure 12-1 Item 1 10) Quantity 217081 Rectifier , Assembly (Includes) 1 .
OM-223 037 Page 66 Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components sepa- rately or as part of the associated wiring harness. Description Part No. Dia. Mkgs. Item No.
OM-223 037 Page 67 Notes 229895 MA TERIAL THICKNESS GAUGE.
OM-223 037 Page 68 Notes 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.welding.org Over 80,000 trained since 1930! Start Y our Professional W elding Career Now!.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Comp any 1635 West Spenc er St reet Applet on, W I 54914 USA International He adquarters .
Een belangrijk punt na aankoop van elk apparaat Miller Electric Big Blue 400 PX (of zelfs voordat je het koopt) is om de handleiding te lezen. Dit moeten wij doen vanwege een paar simpele redenen:
Als u nog geen Miller Electric Big Blue 400 PX heb gekocht dan nu is een goed moment om kennis te maken met de basisgegevens van het product. Eerst kijk dan naar de eerste pagina\'s van de handleiding, die je hierboven vindt. Je moet daar de belangrijkste technische gegevens Miller Electric Big Blue 400 PX vinden. Op dit manier kan je controleren of het apparaat aan jouw behoeften voldoet. Op de volgende pagina's van de handleiding Miller Electric Big Blue 400 PX leer je over alle kenmerken van het product en krijg je informatie over de werking. De informatie die je over Miller Electric Big Blue 400 PX krijgt, zal je zeker helpen om een besluit over de aankoop te nemen.
In een situatie waarin je al een beziter van Miller Electric Big Blue 400 PX bent, maar toch heb je de instructies niet gelezen, moet je het doen voor de hierboven beschreven redenen. Je zult dan weten of je goed de alle beschikbare functies heb gebruikt, en of je fouten heb gemaakt die het leven van de Miller Electric Big Blue 400 PX kunnen verkorten.
Maar de belangrijkste taak van de handleiding is om de gebruiker bij het oplossen van problemen te helpen met Miller Electric Big Blue 400 PX . Bijna altijd, zal je daar het vinden Troubleshooting met de meest voorkomende storingen en defecten #MANUAl# samen met de instructies over hun opplosinge. Zelfs als je zelf niet kan om het probleem op te lossen, zal de instructie je de weg wijzen naar verdere andere procedure, bijv. door contact met de klantenservice of het dichtstbijzijnde servicecentrum.
