Miller Big Blue 400P - Manual

Page 2 - To locate your nearest; Thank you; From Miller to You

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearest distributor or service agency call...

Page 3 - TABLE OF CONTENTS

TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 5 - Declaration of Conformity for; NOTE; Manufacturer; Managing Director; Directives; Arc Welding Equipment

dec_rot_9/06 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Miller Electric Mg. Co. Mr. Danilo Fedolfi, 1635 W. Spencer St. Managing Director Appleton, WI 54...

Page 6 - European Contact Signature:; Sound Level Information

dec_rotsound_6/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Notified Body: Miller Electric Mg. Co. Mr. Danilo Fedolfi, AV Technology Limited 1635 W. Spe...

Page 7 - ELECTRIC SHOCK can kill.; SIGNIFICANT DC VOLTAGE exists in inverters after stop-; FUMES AND GASES can be hazardous.

OM-4421 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoi...

Page 10 - ARC WELDING can cause interference.

OM-4421 Page 4 READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H.F. RADIATION can cause interference. High-frequency (H.F.)...

Page 13 - LA CHUTE DE L’APPAREIL peut blesser.

OM-4421 Page 7 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- ver le bouchon. LES ACCUMULATIONS...

Page 14 - Proposition californienne 65 Avertissements; Principales normes de sécurité; Information EMF

OM-4421 Page 8 LIRE LES INSTRUCTIONS. Utiliser seulement les pièces de rechange d’origine. Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des inter...

Page 15 - Notes; Pros weld and cut

OM-4421 Page 9 SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions (For Wordless Labels) 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. 2 Read Owner’s Manual. Read labels on unit. 3 Use Diesel Fuel only, and fill fuel tank. Leave r...

Page 17 - Some symbols are found only on export products.; Hz

OM-4421 Page 11 3-3. Symbols And Definitions Some symbols are found only on export products. NOTE Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Starting Aid Battery (Engine) Engine Oil Pressure Engine Oil Check Injectors/ Pump Check Valve Clearance Fuel Protective Earth (Ground) Posit...

Page 19 - DC AMPERES

OM-4421 Page 13 4-3. Volt-Ampere Curves For CC Models 215 081-A The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. DC AMPERES DC VOL TS 100 80 60 40 20 0 0 100 200 300 400 ...

Page 21 - DC WELD AMPERES AT 100% DUTY CYCLE

OM-4421 Page 15 4-5. Fuel Consumption The curve shows typical fuel use under weld or power loads. 199 032 − A DC WELD AMPERES AT 100% DUTY CYCLE US Gal./Hr . 0 50 100 150 200 250 300 350 400 450 500 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 IDLE Continuous Welding 4-6. Duty Cycle And Ov...

Page 22 - AC AMPERES IN 240V MODE; AC AMPERES

OM-4421 Page 16 4-7. AC Generator Power Curve 193 018 The ac power curve shows the gen- erator power in 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 VOL TS 0 25 50 75 100 150 125 0 10 20 30 40 50 60 AC AMPERES IN 120V M...

Page 29 - -8. Connecting To Weld Output Terminals

OM-4421 Page 23 5-8. Connecting To Weld Output Terminals 803 602 / 803 778-A Tools Needed: 2 3/4 in 1 MIG and FCAW Welding For MIG and FCAW welding Direct Current Electrode Positive (DCEP) on CC/CV models, connect wire feeder cable to Positive (+) termi- nal on left and work cable to Negative ( − ) ...

Page 31 - -11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models; REMOTE; Start Your Professional

OM-4421 Page 25 5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket* Socket Information 24 VOLTS AC A 24 volts ac. Protected by sup- plementary protector CB5. 24 VOLTS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc i...

Page 38 - Process/Contactor Switch Settings

OM-4421 Page 32 7-3. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch Weld output terminals are ener- gized when Process/Contactor switch is in an Weld Terminals Always On position and the en- gine is running. DC voltage is still present at the weld terminals when Process/ Contact...

Page 47 - -5. Inspecting And Cleaning Optional Spark Arrestor Muffler

OM-4421 Page 41 9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler 803 656 / Ref. 215 158 Stop engine and let cool. 1 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...

Page 49 - -7. Servicing Fuel And Lubrication Systems

OM-4421 Page 43 9-7. Servicing Fuel And Lubrication Systems 802 490 / Ref. 801 434 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. 1 Oil Filter 2 Oil Drain Valve And Hose 3 Oil Fill Cap 4 Fue...

Page 51 - CC Models; Trouble

OM-4421 Page 45 9-9. Troubleshooting A. Welding − CC Models Trouble Remedy No weld output; generator power output okay at ac receptacles. Check position of Ampere Range switch. Check position of optional Polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote posit...

Page 53 - C. Standard Generator Power

OM-4421 Page 47 Trouble Remedy No remote fine amperage or voltage control. Repair or replace remote control device. Have Factory Authorized Service Agent check PC1 sensing leads (36 and 37), and connections. Constant speed wire feeder does not work. Reset supplementary protector CB5 or CB6 (see Sect...

Page 56 - ELECTRICAL DIAGRAMS; Figure 10-1. Circuit Diagram For CC Welding Generator

OM-4421 Page 50 SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator

Page 63 - GENERATOR POWER GUIDELINES; welding generators. Your unit may differ from those shown.; 2-2. Grounding Generator To Truck Or Trailer Frame

OM-4421 Page 57 SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. NOTE 12-1. Selecting Equipment gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacle...

Page 64 - 2-3. Grounding When Supplying Building Systems

OM-4421 Page 58 12-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire.3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE ...

Page 65 - 2-5. Approximate Power Requirements For Industrial Motors

OM-4421 Page 59 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1...

Page 66 - 2-7. Approximate Power Requirements For Contractor Equipment

OM-4421 Page 60 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 ...

Page 68 - 2-10. Typical Connections To Supply Standby Power

OM-4421 Page 62 12-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practic- es. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Customer...

Page 70 - PARTS LIST

OM-4421 Page 64 SECTION 13 − PARTS LIST Hardware is common andnot available unless listed. 400 P Models Only 1 2 3 4 5 6 7 8 9 10 11 13 14 15 12 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 106 107 108 109 110 111 112 113 114 (Fig. 13-2 OR 13-3 115 116 (CC ONLY) 117 118 (CV) 119 (CV) 120 121 1...

Page 77 - CC Models Continued

OM-4421 Page 71 Description Part No. Dia. Mkgs. Item No. Figure 13-2. Control Box Assembly − CC Models Continued Quantity 20 201 079 COVER, control box 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 C9 087 110 CAPACI...

Page 88 - Note; Wiring Harnesses

OM-4421 Page 82 Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness. Note Description Part No. Dia. Mkgs. Item No. Wiring Harnesses Quantity 215054 Harness, co...

Page 91 - (Equipment with a serial number preface of “LH” or newer)

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding ...

Page 92 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service

PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters − USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 E...

Miller Big Blue 400P - Manual

Table of Contents:

Summary

Other Miller Models