Big Blue - Neff Rental

Big Blue - Neff Rental
Big Blue 400 Eco Pro
Issued June 2011 • Index No. ED/5.3
®
Heavy Industrial
Applications
Quick
Specs
Processes
Output Range
Stick (SMAW)
MIG (GMAW)
Flux Cored (FCAW)
DC TIG (GTAW)
Air Carbon Arc (CAC-A)
thru 5/16 in (8 mm) carbons
Pipe Welding
Structural
General Fabrication
Maintenance and Repair
Rental Fleets
Diesel Engine-Driven
Welder/AC Generator
DC CAC-A 20 – 500 A
DC Stick 20 – 450 A
DC TIG 20 – 450 A
MIG/FCAW 14 – 40 V
Generator Output Rated at 104˚F (40˚C)
5500 Watts Peak, 4000 Watts Continuous
Accu-Rated™– Not Inflated
Generator Power
The Power of Blue .
®
EPA Tier 4i
Compliant
The Big Blue 400 Eco Pro is a
rugged, compact, fuel-efficient
diesel welder/generator that’s
Eco-friendly and Eco-nomical.
Mitsubishi S4L2 4-cylinder diesel.
Heavy-duty industrial engine is
designed to operate over 10,000 hours
before the first basic overhaul. Backed
by worldwide support and service.
Superior arc performance
• Factory-preset DIG settings (Stick)
• Hot Start ™ (Stick)
• MIG and Flux Cored arc performance
Simple operation. Operator-friendly
control panel is simplified with colorcoded terminals to get you connected
quickly and correctly.
An Eco-nomical and Eco-friendly
alternative. Designed to be up to
25% more fuel-efficient during
typical welding operations than other
models. Output of the engine matches
the power required, saving operating
cost and the environment. The fuel
savings really add up when running
day-after-day, while producing fewer
carbon emissions. Meets tough EPA
Tier 4i compliance standards.
Meter maintenance displays
• Fuel gauge
• Hour meter function
• Oil change interval
• High coolant temperature and low oil
pressure shutdowns
• Low fuel shutdown — engine shuts
down before system runs out of fuel,
making restarts easy.
Compact package. The Big Blue 400
Eco Pro is up to 44% smaller and
41% lighter than other models —
taking less room and reducing
transportation costs.
Quiet operation. In economy mode with
71.5 dBa at 23 ft (7 m), it’s quieter than
most competitive models, improving
work site communication and safety.
Thermal overload protection prevents
machine damage if the duty cycle is
exceeded or airflow is blocked.
See page 3 for more machine features/benefits.
High efficiency. 3-phase, rotating-field
welding generator requires less fuel and
horsepower to operate.
The Vault — ultimate control
board reliability. See page 4.
Welder/generator is warranted by Miller for 3 years, parts and labor.
Engine is warranted separately by engine manufacturer.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
Weld
Output
Range
Weld Mode
(Subject to change without notice.)
Max. OpenCircuit
Voltage
Weld Output Rated
at 104˚F (40˚C)
CC/DC
(Stick/TIG)
20 – 450 A
300 A, 32 VDC, 100% Duty Cycle
450 A, 30 VDC, 40% Duty Cycle
CV/DC
(MIG/FCAW)
14 – 40 V
300 A, 28 VDC, 100% Duty Cycle
450 A, 30 VDC, 40% Duty Cycle
CC/DC
(CAC-A)
40– 500 A
400 A, 36 VDC, 100% Duty Cycle
500 A, 30 VDC, 40% Duty Cycle
85
Generator Power Output
Rated at 104˚F (40˚C)
Sound Levels at
Rated Output,
23 ft (7 m)
5500 Watts Peak
4000 Watts Continuous
Single-phase, 36/18 A,
120/240 VAC, 60 Hz
Economy Mode:
71.5 dB (96 Lwa);
Power Mode:
81.5 dB (106 Lwa)
Weight
(without
fuel)*
Dimensions
H: 32 in (813 mm)
W: 26-1/4 in (667 mm)
D: 56 in (1422 mm)
Net: 1095 lb
(497 kg)
Ship: 1145 lb
(519 kg)
*Additional 95 lb (43 kg) when fuel tank is full.
Certified by Canadian Standards Association to both the Canadian and U.S. Standards. Meets NEMA and IEC output ratings.
Engine Specifications
Engine
Brand
Mitsubishi
S4L2
(Engines warranted separately by the engine manufacturer.)
Features
HP
Type
EPA Tier 4i compliant, indirect-injected,
liquid-cooled engine. Right-side service access
with intervals of 500 hrs for oil and filters.
35
4-cylinder, industrial
liquid-cooled, diesel
Engine
Speeds
Fuel
Capacity
Oil
Capacity
Coolant
Capacity
Automatic Engine
Shutdown
Idle: 1500 RPM
Weld: 1850 RPM
Gouge: 3000 RPM
11.5 gal
(43.5 L)
6.3 qt
(6 L)
10 qt
(9.5 L)
Low Oil Pressure,
High Coolant
Temperature,
Low Fuel Level
Performance Data
MIG/FCAW MODE V/A CURVE
TIG MODE V/A CURVE
STICK/GOUGE MODE V/A CURVE
100
100
100
80
80
80
60
40
350A – ECONOMY MODE
40
350A – ECONOMY MODE
40
MIN – ECONOMY MODE
100
200
300
400
500
600
700
800
0
900
0
100
200
DC AMPERES
AUXILIARY POWER CURVE
Liters/Hr.
100 200
75 150
50 100
25 50
10
15
20
25
30
35
40
45
US Gal./Hr.
125 250
5
50
AC AMPERES IN 240 V MODE
0
10
20
30 40
50 60
500
0
600
0
100
70
80
3.00
2.75
2.50
2.25
2.00
1.75
1.50
1.25
1.00
0.75
0.50
0.25
0.00
POWER MODE
ECONOMY MODE
STICK/TIG/FCAW
400
300
IDLE
0
200
50 100 150 200 250 300 350 400 450 500
0
10
20
30
40
50
60
% DUTY CYCLE
SIMULTANEOUS WELDING AND POWER TABLE
0/300
500
CAC-A
500
90 100
300/500
400
DUTY CYCLE CURVE
DC WELD AMPERES AT 100% DUTY CYCLE
WELD AMPERES
300
600
AC AMPERES IN 120 V MODE
2
200
DC AMPERES
FUEL CONSUMPTION CURVE
11.36
10.41
9.46
8.52
7.57
6.62
5.69
4.73
3.79
2.84
1.90
.95
0
400
DC AMPERES
150 300
0
300
WELD AMPERES
0
AC VOLTS
60
MAX – POWER
MODE
MIN – ECONOMY MODE
20
MIN – ECONOMY MODE
0
0
MAX – POWER MODE
(GOUGE)
MAX – POWER MODE
MAX – ECONOMY MODE
20
60
DC VOLTS
DC VOLTS
DC VOLTS
MAX – POWER MODE
TOTAL POWER
AVAILABLE IN WATTS
120 V RECEPTACLE
AMPERES
240 V RECEPTACLE
AMPERES
N/A
—
—
4000
20
18
70
80
90
100
Function Guide
1. Optional Self-calibrating Digital Weld
Meters with Fault Code Indication
(order #195 289) display preset or actual
weld parameters.
1
2. Weld Process Select Switch
2
3. Amperage/Voltage Adjust Control
3
6
7
8
4. 14-pin Receptacle* for simple connection
of remote controls. It features Auto Remote
Sense™ which automatically switches from
panel to remote amperage/voltage (A/V)
control with remote connected. Eliminates
confusion of the panel/remote A/V switch.
5. Weatherproof Lexan® Nameplate is super
durable and resists cracking and fading.
Color coded controls for ease of operation.
4
9
5
10
6. Meter Maintenance Displays show fuel
level, engine hours, oil change interval and
hi temp/low pressure/low fuel shutdown
information.
11
12
13
Low Fuel Shutdown shuts engine off prior
to running out of fuel to prevent loss of fuel
in the system, and make restarts easy.
Display will read noFUEL. Turn the machine
off, add fuel, and restart.
MIG/FCAW Position makes it easy to
run all wires from .023 in (0.6 mm)
solid wire to large-diameter 5/64 in
(2.0 mm) flux cored wires.
7. Engine Control Switch is used to start and
stop the engine and select power range.
Auto-Idle is standard.
CAC-A/Stick Position provides
excellent arc characteristics and
makes welding easy. Utilizes Miller’s
Arc-Drive™ to focus the arc and
prevent electrode from going out and
Hot Start™ for positive arc starts to
make it easy to start all types of
electrodes.
8. Glow Plugs assist in cold weather starting.
9. Receptacle and Circuit Breaker Panel
10. CAC-A Positive (+) Gouging Output
Terminal
11. Stick/TIG Positive (+) Weld Output
Terminal
Scratch Start TIG Position.
12. MIG/FCAW Positive (+) Weld Output
Terminal
13. Negative (-) Weld Output Terminal
*Controls only amperage or voltage on the
Big Blue 400 Eco Pro — electrode always hot.
120 V, 20 A
AC Receptacle
120 V, 20 A
AC Receptacle
with Ground Fault
240 V, 20 A
AC Receptacle
Circuit Breakers
3
What Makes Miller Industrial Engine Drives So
Superior Circuit Board Design
Miller’s critical circuit boards are engineered to carry low power
and low heat to reduce thermal stress and minimize expansion
and contraction. In contrast, our competitor’s boards carry high
power and high heat, making them more vulnerable to failure.
?
Rigorous Testing for Tough,
Real-World Conditions
To prove our machines go to the
limit, Miller industrial engine
drives are put to the test in very
extreme environmental conditions.
• Airborne Dust and Sand —
Critical components are
exposed to abusive airborne
particles in a special testing
chamber for weeks, helping
make sure they’ll operate while
facing extreme levels of dirt,
dust or sand on the job site.
“The Vault” Makes Upgrading to Miller CC/CV Units
Worry-Free
Concerns with circuit board reliability have resulted in some
operators steering clear of CC/CV welder/generators — even
though they offer a superior arc and multiple welding processes.
Miller’s circuit board reliability isn’t a concern since all Big Blue
multiprocess industrial engine drives feature the Vault.
Created out of two aluminum halves sealed with silicone, as well
as watertight harness connections, the Vault provides a clean
circuit board environment, protecting the electronics — and
controlling output — in heavy industrial applications. No other
competitor protects their electronics with a sealed vault, leaving
critical circuit boards exposed to harsh elements that can disrupt
the machine’s electronics, and therefore, its operation.
“The Big Blue 400 Eco Pro
reduced our fuel costs by
about 1.6 gallons a day
or more than 31.7 gallons
a month, while its smaller
size and lighter weight has
decreased transportation
costs. Plus, its controls are very easy to use, and the stable,
smooth arc quality has decreased the need for rework. We’re
now more productive and cost efficient.”
Mr. Frank Vucic, Structure Superintendent
McConnell Dowell, South East Asia PTE LTD
“It’s much quieter than our previous machine, making it easier
to communicate on the job site, reducing operator fatigue and
decreasing noise levels in the surrounding communities.”
Mr. RGS Nair, Welding foreman of QCON
4
• Humidity and Corrosion —
Inside Miller’s Houston testing
room, critical components are
subjected to extended moisture
and corrosive salt exposure to
ensure they’ll run even when exposed to humid climates,
corrosive coastal environments, and driving rain.
• Temperature Extremes — Miller’s industrial engine drives
are tested to ensure performance in scorching heat. All Miller
engine driven machines are weld rated at 104˚F, but actual tests
are conducted up to 122˚F to assure peak performance.
• Jobsite/Over-the-Road Abuse — Miller industrial engine
drives are shaken for hours on transportation bed simulators,
subjected to severe vibration, and test-dropped and jerked to
ensure they’ll withstand the stresses that can shut down
competitive machines.
• Continuous Operation — Miller’s industrial engine drives run
day and night, in all weather conditions, to assure they’ll perform
without interruption in the field.
Why Industrial Engine Drive Customers Choose Miller
The ultimate test of Miller’s reliability is how it performs in
the field. The quote on the left provides a glimpse of how
Miller industrial engine drives perform for customers. Read
the full stories, and many others demonstrating Miller’s
superior reliability, at MillerWelds.com.
Genuine Miller Accessories
Cold Weather Starting Aid #300 664 Field
120 V block heater.
Plasma Cutting
Note: All models come standard with preheaters
(glow plugs).
Engine Filter Kit #252 782 Field
Includes all filters required for proper
engine maintenance. Oil filter, primary and
secondary fuel filter, and primary air filter.
Spark Arrestor (Muffler) Kit #300 585 Field
Prevents particles from leaving the muffler
that could potentially start a fire.
FA-1D Lockable Flame
Arrestor Fuel Cap #043 947
Fuel cap can be padlocked to
prevent vandalism. A built-in
flame arrestor prevents
flames or sparks from
entering the fuel tank.
Chalwyn Safety Valve #300 576 Field
Shuts off air flow to the engine to prevent
over-speed condition. Required on many
petroleum jobsites, this valve provides both
manual and automatic operation giving you
two methods of operation to meet jobsite
compliance standards.
Protective Cover #195 301 Field
Blue water-resistant cover with Miller logo
resists stains and mildew, and protects the
finish of your welder.
Stick (SMAW) Welding
Weld Leads
No. 2 Stick Cable Set, 15 ft (4.6 m)
#195 196
Consists of 15 ft (4.6 m) No. 2 electrode
cable with holder, and 15 ft (4.6 m) work
cable with clamp. 200 A, 100% duty cycle.
No. 2 Stick Cable Set, 50 ft (15 m)
#300 836
Consists of 50 ft (15 m) No. 2 electrode
cable with holder, and 50 ft (15 m) work
cable with clamp. 200 A, 100% duty cycle.
2/0 Stick Cable Set, 50 ft (15 m)
#173 851
Consists of 50 ft (15 m) 2/0 electrode
cable with holder, and 50 ft (15 m) work
cable with clamp. 350 A, 100% duty cycle.
2/0 Stick Cable Set, 100/50 ft (30.5/15 m)
#043 952
Consists of 100 ft (30.5 m) 2/0 electrode
cable with holder, and 50 ft (15 m) work
cable with clamp. 300 A, 100% duty cycle.
Spectrum® 375 X-TREME™ #907 339
See Lit. Index No. PC/9.2.
Spectrum® 625 X-TREME™
#907 404 with 12 ft (3.7 m) torch
#907 404-01-1 with 20 ft (6 m) torch
See Lit. Index No. PC/9.6.
The Spectrum 375 X-TREME and 625
X-TREME come complete with protective
X-CASE™ (not shown).
MIG (GMAW) or Flux Cored (FCAW)
Remote Controls
Wireless Remote Foot
Control* #300 429
For remote current
or voltage control.
Receiver plugs directly
into the 14-pin receptacle of Miller
machine. 90 ft (27.4 m) operating range.
Requires Wireless Antenna Kit #300 749.
Wireless Remote Hand
Control* #300 430
For remote current or
voltage control. Receiver
plugs directly into the
14-pin receptacle of Miller machine.
300 ft (91.4 m) operating range. Requires
Wireless Antenna Kit #300 749.
Wireless Antenna Kit #300 749
Required for Pro Series engine drives.
Optional on other compatible Miller products
where improved reception is desired.
RFCS-14 HD Foot Control* #194 744
Heavy-duty foot current or voltage control.
Includes 20 ft (6 m) cord and 14-pin plug.
SuitCase® X-TREME™ 8VS Wire Feeder
#951 182
SuitCase® X-TREME™ 12VS Wire Feeder
#951 184
Lightweight, voltage-sensing wire feeders
include secondary contactor, gas valve and
drive roll kit. See Lit. Index No. M/6.41.
TIG (GTAW) Welding
HF-251 Series
#042 388
HF-251D-1, 115 VAC
#042 387
HF-251-2, 230 VAC
High-frequency arc
starter and stabilizer.
Corresponding Secondary Contactors
listed below are recommended when using
HF Series with Eco Pro engine drives. See
Accessory Lit. Index No. AY/5.0.
Secondary Contactor Kit
#041 969 Field. For HF-251D-1
#041 906 Field. For HF-251-2
For power sources without a contactor.
Mounts inside HF-251 cabinet.
RHC-14 Hand Control* #242 211 020
Miniature hand current or voltage control.
Dimensions: 4 x 4 x 3-1/4 in (102 x 102 x
82 mm). Includes 20 ft (6 m) cord and
14-pin plug.
PRHC-14 Hand Control*
#195 511
Complete current or voltage
control brings 120 volts
GFCI power to work area in
a single cord. Housed in a durable light
aluminum case and includes 125 ft (38 m)
cord with plugs.
RCC-14 Remote Fingertip Control*
#151 086 14-pin plug
Rotary-motion fingertip control fastens to
TIG torch using two Velcro® straps.
Includes 28 ft (8.5 m) control cord.
Extension Cords for 14-Pin Remote Controls
#242 208 025 25 ft (7.6 m)
#242 208 050 50 ft (15.2 m)
#242 208 080 80 ft (24.4 m)
*Controls only amperage or voltage on the
Big Blue 400 Eco Pro — electrode always hot.
5
Trailers and Hitches
Mounting Specifications
(Note: Trailers are shipped unassembled.)
F
A
4 West Four-Wheel Steerable
Off-Road Trailer #042 801
A heavy-duty 2570 lb (1166 kg) capacity
trailer designed for use in mines, quarries,
and other rough terrain. Has narrow
22 ft (6.7 m) turning radius. Includes
3 in (76 mm) lunette eye, universal hitch
and safety chains.
Note: Trailer is shipped unassembled.
HWY-224 Trailer
#043 805 For highway use.
OFR-224 Trailer
#043 802 For off-road use.
A 2650 lb (1202 kg) capacity trailer.
Welded steel tubing frame, heavy-duty axle
with roller bearing hubs and leaf-spring
suspension. Includes jack stand, 2 in
(50 mm) ball hitch. HWY-224 also includes
fenders and lights.
Note: Trailer is shipped unassembled.
Cable Tree #043 826
Provides an area to conveniently wrap weld
cables and extension cords.
B
4 holes
Front Panel
C
D
E
A. 27-3/4 in (705 mm)
B. 26-1/4 in (667 mm)
C. 52 in (1321 mm)
D. 2 in (51 mm)
E. 56 in (1422 mm)
F. 9/16 in (14 mm) dia.
Height: 32 in (813 mm)
Width: 26-1/4 in (667 mm)
Depth: 56 in (1422 mm)
Dual Hitch #300 831
2 in (50 mm) ball hitch and 3 in (76 mm)
lunette eye in one reversible assembly.
Trailer Specifications
(Subject to change without notice.)
Gross Axle
Weight Rating
Gross Vehicle
Weight Rating
Net
Payload
Height
of Bed
Road
Clearance
Track (Center
to center of
tires)
Standard Tires
(Standard rating
or P-size rating)
4-West
2000 lb/axle
(907 kg/axle)
3000 lb
(1361 kg)
2570 lb
(1166 kg)
21-1/4 in
(540 mm)
8 in
(203 mm)
55-1/4 in
(1403 mm)
HWY-224
OFR-224
3500 lb
(1588 kg)
2960 lb
(1343 kg)
2650 lb
(1202 kg)
18-1/2 in
(470 mm)
7-1/2 in
(191 mm)
52 in
(1321 mm)
Model
*Does not include tongue. **Width at outside of fenders.
6
Dimensions
Net
Weight
B78-13
Length: 91 in (2311 mm)*
Width: 61-1/4 in (1556 mm)
430 lb
(195 kg)
B78-13
Length: 105 in (2667 mm)
Width: HWY– 59-1/2 in (1511 mm)**
OFR– 58-7/16 in (1484 mm)
320 lb
(145 kg)
Typical Installations
Stick (SMAW) and Air Carbon Arc Cutting and
Gouging (CAC-A) Basic Equipment
PRHC-14
Wireless Remote Hand Control
Wireless Antenna Kit
#195 511
#300 430
#300 749
MIG/Flux-Cored (FCAW) Basic Equipment
™
®
SuitCase X-TREME 8VS
SuitCase® X-TREME™ 12VS
#951 182
#951 184
Remote Control
Electrode/Carbon
14-Pin PRHC-14 OR Wireless
Remote
Hand Control
Work
SuitCase
X-TREME
8VS/12VS
MIG/Flux Cored Gun
Work
TIG
Torch
Lift-Arc™ TIG (GTAW) Basic Equipment
Work
Cutting Torch
Plasma Basic Equipment
Spectrum 375 X-TREME #907 339
Spectrum® 625 X-TREME™
#907 404 with 12 ft (3.7 m) torch
#907 404-01-1 with 20 ft (6 m) torch
®
™
Spectrum
Work
7
Ordering Information
Equipment and Options
Big Blue 400 Eco Pro (CC/CV)
Stock No.
Description
#907 426
Base machine
#907 426-001
With Weld Meters and 120 V Block Heater
Digital Weld Meter Kit
#195 289
Field
Cold Weather Starting Aid
#300 664
Field. 120 V block heater
Engine Filter Kit
#252 782
Field. Includes air, oil and fuel filters
Spark Arrestor Kit
#300 585
Field
FA-1D Lockable Flame Arrestor Fuel Cap
#043 947
Field
Chalwyn Safety Valve
#300 576
Field
Protective Cover
#195 301
Field
®
Qty.
Field Accessories
Stick Welding Leads
See page 5
Plasma Cutting
Spectrum® 375 X-TREME™
#907 339
Includes X-CASE™. See Lit. Index No. PC/9.2
Spectrum® 625 X-TREME™
#907 404
#907 404-01-1
With 12 ft (3.7 m) torch and X-CASE™. See Lit. Index No. PC/9.6
With 20 ft (6 m) torch and X-CASE™. See Lit. Index No. PC/9.6
#951 182
See Lit. Index No. M/6.41
#951 184
See Lit. Index No. M/6.41
HF-251 Series
(Secondary Contactor Recommended)
#042 388
#042 387
HF-251D-1, 115 VAC. See Lit. Index No. AY/5.0
HF-251-2, 230 VAC. See Lit. Index No. AY/5.0
Secondary Contactor Kit
#041 969
#041 906
Field. For HF-251D-1
Field. For HF-251-2
Wireless Remote Foot Control
#300 429
Amperage or voltage control only — electrode always hot.
Requires Wireless Antenna Kit
Wireless Remote Hand Control
#300 430
Amperage or voltage control only — electrode always hot.
Requires Wireless Antenna Kit
Wireless Antenna Kit
#300 749
Required for wireless remotes when using Pro Series engine drives
RFCS-14 HD Foot Control
#194 744
Amperage or voltage control only — electrode always hot
RHC-14 Hand Control
#242 211 020
Amperage or voltage control only — electrode always hot
PRHC-14 Hand Control
#195 511
Amperage or voltage control only — electrode always hot
RCC-14 Remote Fingertip Control
#151 086
Amperage or voltage control only — electrode always hot
MIG/Flux Cored Welding
SuitCase® X-TREME™ 8VS
™
SuitCase X-TREME 12VS
®
TIG Welding
Remote Controls and Switches
Extension Cords
See page 5
Trailers and Hitches
4-West Four-Wheel Steerable Trailer
#042 801
Trailer with lunette eye, universal hitch and safety chains. For off-road use
HWY-224 Trailer
#043 805
Trailer with lights, fenders and 2 in (50 mm) ball hitch. For highway use
OFR-224 Trailer
#043 802
Trailer with 2 in (50 mm) ball hitch. For off-road use
Cable Tree
#043 826
Trailer-mounted cable holder for HWY-224 or OFR-224
Dual Hitch
#300 831
Combination 2 in (50 mm) ball hitch and 3 in (76 mm) lunette eye in one
reversible assembly. For HWY-224 or OFR-224
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Price
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