Miller Electric Big Blue 400P Owner's Manual
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Miller Electric Big Blue 400P Owner's Manual

Engine driven welding generator
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www.MillerWelds.com
Big Blue 400P
Big Blue 500 X
(Perkins-Powered)
OM-4421
2007−10
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
R
R
File: Engine Drive
215 075Q

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  • Page 1 Visit our website at www.MillerWelds.com Big Blue 400P Big Blue 500 X (Perkins-Powered) OM-4421 215 075Q 2007−10 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator File: Engine Drive...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 TABLE OF CONTENTS SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 7-3. Process/Contactor Switch On CC/CV Models 7-4.
  • Page 5 European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Manufacturer: Miller Electric Mg. Co. 1635 W. Spencer St. Appleton, WI 54914 USA Phone: (920) 734-9821 European Contact Signature: Big Blue 500 X...
  • Page 6 Declaration of Conformity for European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Manufacturer: Miller Electric Mg. Co. 1635 W. Spencer St. Appleton, WI 54914 USA Phone: (920) 734-9821 European Contact Signature:...

  • Page 7: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 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. The possible hazards are shown in the adjoining symbols or explained in the text.

  • Page 8: Noise Can Damage Hearing

    FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.

  • Page 9: Engine Hazards

    1-3. Engine Hazards BATTERY EXPLOSION can BLIND. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Stop engine before disconnecting or connect- ing battery cables or servicing battery. D Do not allow tools to cause sparks when working on a battery. D Do not use welder to charge batteries or jump start vehicles.

  • Page 10: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and gouging can cause fire or explosion. D Do not cut or gouge near flammables. D Watch for fire; keep extinguisher nearby. HOT PARTS can cause burns and injury. D Do not touch hot compressor or air system parts.

  • Page 11: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

  • Page 12: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
  • Page 13 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. D Ne pas toucher à mains nues les parties chau- des. D Prévoir une période de refroidissement avant de travailler à l’équipement. D Ne pas toucher aux pièces chaudes, utiliser les outils recomman- dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.

  • Page 14: Dangers Existant En Relation Avec Le Moteur

    LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux. D Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance. D Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de sou- dage par points, de gougeage, du coupage plasma ou de chauf- fage par induction.

  • Page 15: Dangers Liés À L'air Comprimé

    L’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. D Les fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore. D JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes. D Uniquement utiliser à...
  • Page 16 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. D Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur. D 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.

  • Page 17: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements 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. (Code de santé...

  • Page 18: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions (For Wordless Labels) 0 − 50 h Std. 50 h Std. Notes OM-4421 Page 12 S-177 571 DIESEL 200A 0 − 200A API CD-MIL L 2104D, CD/SE, CD/SF Remove unit from shipping crate.

  • Page 19: Manufacturer's Rating Labels

    3-2. Manufacturer’s Rating Labels CC Models CC/CV Models CC Export Models CC/CV Export Models OM-4421 Page 13...

  • Page 20: Symbols And Definitions

    3-3. Symbols And Definitions Some symbols are found only on export products. Stop Engine Starting Aid Check Injectors/ Pump Positive Amperes Engine Stick (SMAW) Welding Time Three Phase Electrode Connection Duty Cycle Rated Idle Speed Contactor On OM-4421 Page 14 Fast (Run, Weld/ Power) Battery (Engine)

  • Page 21: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Welding Weld Output Rated Welding Mode Range Output Export Models: 300 A, 32 Volts DC, 100% Duty Cycle 55 − 500 A 430 A, 37 Volts DC, (CC Models) CC/DC 60% Duty Cycle 15 −...

  • Page 22: Volt-Ampere Curves For Cc Models

    4-3. Volt-Ampere Curves For CC Models Notes OM-4421 Page 16 Ranges: 230 − Max 170 − 365 110 − 225 70 − 130 55 − 85 400 500 900 1000 DC AMPERES The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator.

  • Page 23: Volt-Ampere Curves For Cc/Cv Models

    4-4. Volt-Ampere Curves For CC/CV Models A. Stick Mode DC AMPERES B. MIG Mode C. TIG Mode DC AMPERES RANGES: 155 − 450 115 − 320 75 − 195 40 − 90 400 500 900 1000 900 1000 DC AMPERES RANGES: 60 −...

  • Page 24: Fuel Consumption

    4-5. Fuel Consumption 2.50 2.25 2.00 1.75 1.50 1.25 1.00 0.75 0.50 IDLE 0.25 0.00 DC WELD AMPERES AT 100% DUTY CYCLE 4-6. Duty Cycle And Overheating OM-4421 Page 18 100% Duty Cycle At 400 Amperes Continuous Welding The curve shows typical fuel use under weld or power loads.

  • Page 25: Ac Generator Power Curve

    4-7. AC Generator Power Curve AC AMPERES IN 240V MODE AC AMPERES IN 120V MODE 4-8. Optional Three-Phase Generator Curves A. 12 kVA/kW Single-Phase AC Output (No Weld Load) AC AMPERES B. 15 kVA/kW Three-Phase AC Output (No Weld Load) 90 100 AC AMPERES The ac power curve shows the gen-...

  • Page 26: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Movement Location/Airflow Clearance 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) (460 mm) Grounding GND/PE OM-4421 Page 20 18 in (460 mm) 18 in Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica-...

  • Page 27: Using Lifting Eye

    5-2. Using Lifting Eye Notes Lifting Eye Carriage Bolt Raise lifting eye until it snaps in place. Lower lifting eye when not needed. To lock the lifting eye in the upright position, insert a 3/8-16 x 1-1/2 in carriage bolt through slot in bracket and secure with nut (bolt and nut not supplied).

  • Page 28: Mounting Welding Generator

    5-3. Mounting Welding Generator Supporting The Unit Using Mounting Brackets Tools Needed: 9/16 in OM-4421 Page 22 Welding Unit In Place Bolting Unit In Place install3 2007−046 803 274 / 200 864-A / 803 602 Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion.

  • Page 29: Installing Exhaust Pipe

    5-4. Installing Exhaust Pipe Tools Needed: 1/2 in Notes Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Ref. 803 604 / Ref. 215 158 Work like a Pro! Pros weld and cut safely.

  • Page 30: Activating The Dry Charge Battery (If Applicable)

    5-5. Activating The Dry Charge Battery (If Applicable) 5 A For 30 Minutes 30 A For 12 Minutes Tools Needed: 5-6. Connecting The Battery Connect negative (−) cable last. Tools Needed: 1/2 in OM-4421 Page 24 − − Always wear a face shield, rubber gloves and protective clothing when working on a battery.

  • Page 31: Engine Prestart Checks

    5-7. Engine Prestart Checks Full Diesel Check all engine fluids daily. Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.

  • Page 32: Connecting To Weld Output Terminals

    5-8. Connecting To Weld Output Terminals Stop engine. Positive (+) Weld Output Terminal Negative (−) Weld Output Terminal Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar Remove supplied nut from weld output termi-...

  • Page 33: Selecting Weld Cable Sizes

    5-9. Selecting Weld Cable Sizes* Weld Output Terminals Stop engine before Welding connecting to weld Amperes output terminals. Do not use worn, dam- aged, undersized, or poorly spliced cables. Chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable. **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

  • Page 34: Connecting To Remote 14 Receptacle Rc14 On Cc/Cv Models

    5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models *The remaining sockets are not used. Notes Start Your Professional Welding Career Now! OM-4421 Page 28 24 VOLTS AC 24 VOLTS AC REMOTE OUTPUT OUTPUT CONTROL 115 VOLTS AC NEUTRAL Ref.
  • Page 35 Notes OM-4421 Page 29...

  • Page 36: Section 6 − Operating Welding Generator − Cc Models

    SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 215 070 / 803 602 OM-4421 Page 30...

  • Page 37: Description Of Front Panel Controls For Cc Models (See Section 6-1)

    6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) Engine Starting Controls Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). Engine Control Switch Use switch to start and stop engine. To Start: NOTICE −...

  • Page 38: Remote Amperage Control On Cc Models (Optional)

    6-3. Remote Amperage Control On CC Models (Optional) Example: Combination Remote Amperage Control (Stick) Set Switches Set Range 6-4. Weld Control/Arc Condition Information Label OM-4421 Page 32 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-10). In Example: Range = 110 to 225 A DC Percentage Of Range = 50%...
  • Page 39 Notes OM-4421 Page 33...

  • Page 40: Section 7 − Operating Welding Generator − Cc/Cv Models

    SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 215 158 / 803 602 OM-4421 Page 34...

  • Page 41: Description Of Front Panel Controls For Cc/Cv Models (See Section 7-1)

    7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) Engine Starting Controls Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). Engine Control Switch Use switch to start engine, select engine speed ( if unit has auto idle option), and stop engine.

  • Page 42: Process/Contactor Switch On Cc/Cv Models

    7-3. Process/Contactor Switch On CC/CV Models Switch Setting Switch Setting Remote On/Off Switch Re- GTAW With HF Unit, Pulsing quired − TIG, HF Required Device, Or Remote Control Or Scratch Start TIG Remote On/Off Switch Stick (SMAW) With Remote On/Off Required −...

  • Page 43: Remote Voltage/Amperage Control On Cc/Cv Models (Optional)

    7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) Example: Combination Remote Amperage Control (Stick) Set Remote Set V/A Adjust Switch Process Example: Combination Remote Amperage Control (TIG) Set V/A Set Remote Process Adjust Switch Process = Stick (Using Remote On/Off) Set Range Control Not Used In Remote...

  • Page 44: Section 8 − Operating Auxiliary Equipment

    SECTION 8 − OPERATING AUXILIARY EQUIPMENT 8-1. 120 Volt And 240 Volt Receptacles OM-4421 Page 38 120 V 20 A AC GFCI Receptacle GFCI1 240 V 30 A AC Twistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, GFCI Reset button...

  • Page 45: Connecting To Optional Three-Phase Generator (Cc/Cv Models Only)

    8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) Single-Phase Power Connection Three-Phase Power Connection Y Close panel opening if no connections are made to generator. Remove plug before inserting leads. Reinstall bushing. Rear Of Panel 120V 120V Single Phase Output Volts 120/240...

  • Page 46: Optional Generator Power Receptacles

    8-3. Optional Generator Power Receptacles European Receptacle Australian Receptacle South African Receptacle OM-4421 Page 40 120 V 20 A AC GFCI Receptacle GFCI1 240 V 16 A AC European Receptacle RC1 240 V 15 A AC Australian Receptacle RC1 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.

  • Page 47: Section 9 − Maintenance & Troubleshooting

    SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Maintenance Label OM-4421 Page 41...

  • Page 48: Routine Maintenance

    9-2. Routine Maintenance n = Check Z = Change * To be done by Factory Authorized Service Agent Every FUEL WATER Hours n Fuel/Water Separator n Fuel Level n Coolant Level Every Hours ~ Weld Terminals Every Hours ~ Battery Terminals n Air Cleaner Hoses Every Hours...

  • Page 49: Checking Generator Brushes

    9-3. Checking Generator Brushes Notes Minimum Length: 5/8 in (16 mm) New Length: 1-1/4 in (32 mm) Replace Damaged Brushes Stop engine and let cool. Generator Brush Mark and disconnect leads at brush hold- er cap. Remove brushes. Replace brushes if damaged or if brush material is at or near minimum length.

  • Page 50: Servicing Air Cleaner

    9-4. Servicing Air Cleaner Keep nozzle 2 in (51 mm) from element. Blow OM-4421 Page 44 Optional Inspect aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 215 158 Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element.

  • Page 51: Inspecting And Cleaning Optional Spark Arrestor Muffler

    9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler Tools Needed: 3/8 in Stop engine and let cool. Spark Arrestor Muffler 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 out of hole, briefly cover end of exhaust pipe with fireproof material.

  • Page 52: Adjusting Engine Speed

    9-6. Adjusting Engine Speed To prevent solenoid damage, be sure a 1/8 in (3 mm) gap exists between the engine low speed screw and throttle lever when the solenoid is held in the energized position. OM-4421 Page 46 Engine Speed (No Load) 1850 rpm max (61.6 Hz)

  • Page 53: Servicing Fuel And Lubrication Systems

    9-7. Servicing Fuel And Lubrication Systems 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. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Fuel Line Primary Fuel Filter (Fuel/ Water Separator)

  • Page 54: Overload Protection

    9-8. Overload Protection OM-4421 Page 48 Stop engine. When a supplementary protector, circuit breaker or fuse opens, it usu- ally indicates a more serious problem exists. Contact Factory Authorized Service Agent. Fuse F1 Fuse F2 F1 and F2 protect the stator exciter wind- ing from overload.

  • Page 55: Troubleshooting

    9-9. Troubleshooting A. Welding − CC Models Trouble No weld output; generator power output Check position of Ampere Range switch. okay at ac receptacles. Check position of optional Polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote control to Remote Amperage Adjust receptacle RC13 (see Sections 5-10 and 6-1).
  • Page 56 Trouble No remote fine amperage control. Repair or replace remote control device. Have Factory Authorized Service Agent check OCV control circuit. B. Welding − CC/CV Models Trouble No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote okay at ac receptacles.
  • Page 57 Trouble No remote fine amperage or voltage Repair or replace remote control device. control. Have Factory Authorized Service Agent check PC1 sensing leads (36 and 37), and connections. Constant speed wire feeder does not Reset supplementary protector CB5 or CB6 (see Section 9-8). work.
  • Page 58 E. Engine Trouble Engine will not crank. Check battery, and replace if necessary. Check battery connections and tighten if necessary. Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9-8). Have Factory Authorized Service Agent check engine wiring harness and components. Check engine wiring harness plug connections.
  • Page 59 Notes Welding Symbols Ref. AWS/ANSI A2.4 OM-4421 Page 53...

  • Page 60: Circuit Diagram For Cc Welding Generator

    SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator OM-4421 Page 54...
  • Page 61 223 522-B OM-4421 Page 55...
  • Page 62 Figure 10-2. Circuit Diagram For CC/CV Welding Generator OM-4421 Page 56...
  • Page 63 223 523-B OM-4421 Page 57...

  • Page 64: Section 11 − Run-In Procedure

    SECTION 11 − RUN-IN PROCEDURE 11-1. Wetstacking OM-4421 Page 58 run_in1 2007−04 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. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.

  • Page 65: Run-In Procedure Using Load Bank

    11-2. Run-In Procedure Using Load Bank 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 equip- ment damage may occur.

  • Page 66: Run-In Procedure Using Resistance Grid

    11-3. Run-In Procedure Using Resistance Grid OM-4421 Page 60 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 equip- ment damage may occur.

  • Page 67: Section 12 − Generator Power Guidelines

    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. 12-1. Selecting Equipment 12-2. Grounding Generator To Truck Or Trailer Frame GND/PE Generator Power Receptacles −...

  • Page 68: Grounding When Supplying Building Systems

    12-3. Grounding When Supplying Building Systems 12-4. How Much Power Does Equipment Require? OM-4421 Page 62 GND/PE VOLTS 115 AMPS Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. Ground Device Use ground device as stated in electrical codes.
  • Page 69 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 12-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 70 12-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...

  • Page 71: Power Required To Start Motor

    12-8. Power Required To Start Motor Motor Start Code KVA/HP 12-9. How Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements 10.0 AC MOTOR VOLTS AMPS CODE PHASE 11.2 12.5 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
  • Page 72 12-10. Typical Connections To Supply Standby Power Utility Electrical Transfer Switch Service Essential Loads OM-4421 Page 66 Fused Welding Disconnect Generator Switch Output (If Required) Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install and ground this equipment according to its Owner’s Manual and na-...

  • Page 73: Selecting Extension Cord (Use Shortest Cord Possible)

    12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 74: Section 13 − Parts List

    SECTION 13 − PARTS LIST 400 P Models Only 125 (Fig. 13-4 OR 13-5) Figure 13-1. Main Assembly (Export Model Shown) OM-4421 Page 68 118 (CV) 119 (CV) Fig. 13−7 114 (Fig. 13-2 OR 13-3 116 (CC ONLY) Hardware is common and not available unless listed.
  • Page 75 93 (Fig. 13−6) 803 646-E OM-4421 Page 69...
  • Page 76 Item Dia. Part Mkgs. Figure 13-1. Main Assembly ....189 824 ....♦199 294 .
  • Page 77 Item Dia. Part Mkgs. Figure 13-1. Main Assembly (Continued) ....♦202 629 ....191 354 .
  • Page 78 Item Dia. Part Mkgs. Figure 13-1. Main Assembly (Continued) ....191 626 ....199 592 .
  • Page 79 Item Dia. Part Mkgs. Figure 13-1. Main Assembly (Continued) ... ♦199 305 ... . 212 944 ......
  • Page 80 Figure 13-2. Control Box Assembly − CC Models Item Dia. Part Mkgs. Figure 13-2. Control Box Assembly − CC Models (Figure 13-1 Item 114) ..F1, F2 *085 874 ....046 432 .
  • Page 81 Item Dia. Part Mkgs. Figure 13-2. Control Box Assembly − CC Models Continued ....201 079 ... . . 087 110 .
  • Page 82 Figure 13-3. Control Box Assembly − CC/CV Models Item Dia. Part Mkgs. Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 114) ..F1, F2 *085 874 ....046 432 .
  • Page 83 Item Dia. Part Mkgs. Figure 13-3. Control Box Assembly − CC/CV Models (Continued) ....177 136 ..D1/C1 189 701 .
  • Page 84 Hardware is common and not available unless listed. 803 649 Figure 13-4. Panel, Front w/Components − CC Models OM-4421 Page 78...
  • Page 85 Item Dia. Part Mkgs. Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 125) ....215 070 .......
  • Page 86 Item Dia. Part Mkgs. Figure 13-4. Panel, Front w/Components − CC Models (Continued) ....197 798 ....217 083 .
  • Page 87 Item Dia. Part Mkgs. Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 125) ....215 158 .......
  • Page 88 Item Dia. Part Mkgs. Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued) ....134 201 ....181 169 .
  • Page 89 Hardware is common and not available unless listed. Item Dia. Part Mkgs....132 053 ....183 387 .
  • Page 90 Item Dia. Part Mkgs....197 486 ....083 883 .
  • Page 91 Hardware is common and not available unless listed. Item Dia. Part Mkgs....215 910 ....188 137 .
  • Page 92 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 harnes Item Dia. Part Mkgs..... 215054 .
  • Page 93 Item Dia. Part Mkgs..... 221376 D10/C10, D11/C11 . . . 189701 ..CB10 .
  • Page 95 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.

  • Page 96: Owner's Record

    For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © 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...

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