User manual | Big Blue® 400PipePro

Issued Aug. 2017 • Index No. ED/5.8
Big Blue 400 PipePro
®
Heavy Industrial
Applications
Quick
Specs
Cross-country pipeline
Process pipe welding
®
Processes
Diesel Engine-Driven
Welder/AC Generator
Output Range DC stick 20–400 A
Stick (SMAW)
MIG (GMAW)
Flux-cored (FCAW)
RMD®
Pulsed MIG (GMAW-P)
DC TIG (GTAW)
Air carbon arc (CAC-A)
Rated: 1/4-inch (6.4 mm) carbons
DC TIG 20–400 A
FCAW/MIG 14–40 V
Generator Output Rated at 104°F (40°C)
12,000 watts peak, 10,000 watts continuous
Designed for the transmission pipeline welder.
The Big Blue 400 PipePro offers superior downhill stick arc characteristics,
as well as MIG/flux-cored capabilities, to meet high-strength steel requirements
for the most demanding pipeline jobs.
DURABLE
BUILT
TO LAST
Built to last in harsh
industrial environments
Mitsubishi S4L2 four-cylinder diesel.
Heavy-duty low-speed T4F
industrial diesel engine designed
to operate over 10,000 hours before
the first basic overhaul. Backed by
worldwide support and service.
SUPERIOR
ARC
PERFORMANCE
Processes optimized for
pipeline welding
Remote control of the power source
without a cord. See pages 2 and 3.
DYNAMIC
DIG
Exclusive stick arc control
technology for
fine-tune adjustments
COMPACT SIZE
Also available with stainless
steel enclosure. See page 8.
Perfect for mobile
welding rigs
Welder/generator is warranted by Miller for three years, parts and labor.
Engine is warranted separately by engine manufacturer.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
An ITW Welding Company
1635 West Spencer Street
P.O. Box 1079
Appleton, WI 54912-1079 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
MillerWelds.com
Big Blue 400 PipePro Features and Controls
®
®
Arc control allows arc characteristics
to be adjusted in stick and wire
processes. In stick modes, unlock
the benefits of the all-new Miller®
Dynamic DIG program, which gives
welders the fine-tuning they need to
overcome issues related to fitup and
inconsistencies in the pipe.
Digital meters with SunVision™
technology enable welding parameters
to be viewed with greater clarity than
analog meters — at virtually any angle.
Meters can be seen clearly even in
direct sunlight.
Meters display
• Process settings for quick and
easy setup
• Preset and actual amperage
Standard 14-pin receptacle with
Auto-Remote Sense™ for simple
connection of remote controls and
wire feeders.
Simple-to-set controls
require no elaborate procedure —
just select process and weld!
Industrial USB port.
Quickly upload the
latest software and
download machine
log files to retrieve
in-depth information such as
diagnostics and machine statistics.
POWERFUL
GENERATOR
10,000 watts of pure generator
power. Plug in an extra Miller®
inverter-based power source for a
second welding arc!
Low OCV stick (VRD), when enabled,
reduces the open-circuit voltage to
30 volts when the welding power source
is not in use, increasing operator safety
without compromising arc starts.
Optional stainless steel enclosure.
Enhances durability and adds to the
look and resale value of the machine.
LINE-X® top cover
is workbench
tough and provides superior impact,
corrosion and abrasion protection.
Standard features include adjustable Hot Start,™ output contactor
control, automatic idle, thermal overload protection and 120-volt
block heater.
®
ArcReach Remote Control Technology
ArcReach
feeder or remote
Remote control of the power source
without a control cord.
An ArcReach system allows you to change
weld settings from your ArcReach feeder
or remote, saving a trip to the power
supply. ArcReach technology uses the
existing weld cable to communicate
welding control information between the
feeder or remote and the power source.
This technology eliminates the need for
control cords, and their associated
problems and costs.
2
ArcReach
engine drive
Quiet operation. Improves jobsite
communication.
®
Big Blue 400 PipePro Additional ArcReach Features
®
®
ArcReach provides remote amperage and voltage control at the weld joint without needing a control cord.
MORE
WELDS
IN LESS
TIME
Increased productivity
BETTER
WELDS
WITH LESS
REWORK
Automatic return to panel settings. System automatically
returns to Big Blue 400 PipePro setting when ArcReach
communication is terminated. For example, if the Big Blue
is set to gouging at 350 amps and an ArcReach feeder is
connected, the Big Blue will go to a MIG/FCAW process.
If the feeder is disconnected, the Big Blue will go back to
its previous setting (gouging at 350 amps).
More arc-on time and reduced exposure to workplace
hazards for operators can be realized using ArcReach
because less time is spent going back to the welding power
supply to set process and arc amperage or voltage.
Auto-Process Select.™ Depending on connected accessory,
the system automatically changes to stick or MIG/FCAW
(with gas) if electrode positive polarity is detected or TIG
or FCAW (no gas) if electrode negative polarity is detected,
when ArcReach communication is established between the
accessory and the Big Blue 400 PipePro — reducing the
need to access the power supply.
Less operator fatigue by not needing to move or reposition
heavy secondary weld leads bundled with control cords on
the jobsite. Control cords are not used.
Operator can precisely set arc amperage or voltage at the
weld joint and monitor the actual arc voltage and current
delivered to the weld using the digital meters on the
accessory. This removes guesswork when it comes to
adhering to weld procedures.
Remote override of Big Blue 400 PipePro. When an
ArcReach accessory is connected to a Big Blue the
accessory has full control and the Big Blue controls
are disabled. While under ArcReach control, process
and voltage/amperage adjustments are locked out,
preventing accidental changes by personnel other than
the welding operator.
Save time by no longer needing to troubleshoot welding
system problems that result from damaged control cords.
Eliminate costly control cord repairs because control
cords are not used.
Cross platform compatible. The same ArcReach
accessories that work on engine-driven equipment can
also be used on select ArcReach-equipped XMT® and
Dimension™ power sources.
Reverse compatible. ArcReach-equipped power sources
work with non-ArcReach accessories; however, the
complete ArcReach benefit is only realized with the
ArcReach system.
Improved weld quality
FEWER
CABLES
TO MAINTAIN
Reduced maintenance
FLEET COMPATIBILTY
Improved flexibilty
®
Big Blue 400 PipePro System and ArcReach Accessories
®
®
Big Blue 400 PipePro system (stainless steel
enclosure, Mitsubishi, 907703), ArcReach
SuitCase® 12 feeder with Bernard™ S-Gun™
(951730), ArcReach Stick/TIG Remote (301325),
and ArcReach Smart Feeder with Bernard
PipeWorx 300-15 MIG gun (951733).
ArcReach SuitCase 8 and 12
feeders for MIG or flux-cored
welding
• Remote voltage control
• Polarity indication
• Auto-Process Select™
ArcReach Smart Feeder
for advanced wire processes
• RMD® and pulsed MIG
processes
• Remote voltage control
• Store and recall weld settings
ArcReach Stick/TIG Remote for stick or TIG welding
• Remote amperage control • Arc control for stick
• Polarity indication
• Auto-Process Select™
3
Specifications (Subject to change without notice.)
Weld
Output
Range
Weld Output Rated
at 100% Duty Cycle
at 104°F (40°C)
Max. OpenCircuit
Voltage
Generator Power Output
Rated at 104°F (40°C)**
Sound Levels
at Rated Output,
23 ft. (7 m)
CC/DC
(TIG)
20–400 A
85 VDC
30 VDC*
12,000 watts peak,
10,000 watts continuous
Idle: 68.7 dB (93 Lwa)
Weld: 72.1 dB (97 Lwa)
CC/DC
(Stick)
20–400 A
300 A at 32 VDC
350 A at 27 VDC
400 A at 24 VDC
CV/DC
(FCAW/MIG)
14–40 V
Weld Mode/
Process
1-phase, 84/42 A,
120/240 VAC, 60 Hz
*Sense voltage for stick and Lift-Arc™ TIG. **Will operate either 60 Hz or 50/60 Hz power tools, lights, etc.
Net Weight
(without fuel)***
Dimensions
H: 32 in.
(813 mm)
W: 26.25 in.
(667 mm)
D: 56 in.
(1,422 mm)
993 lb. (450 kg)
***Additional 82 lb. (37 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 (Engines warranted separately by the engine manufacturer.)
Engine Brand
Features
HP
Type
Engine Speeds
Capacities
Automatic Engine
Shutdown
Mitsubishi S4L2
EPA Tier 4 Final compliant,
includes 120 V block heater
24.7
Four-cylinder, liquid-cooled,
industrial diesel
Idle: 1,500 rpm
Weld: 1,800 rpm
Fuel: 11.5 gal. (43.5 L)
Oil: 5.8 qt. (5.5 L)
Coolant: 10 qt. (9.5 L)
Low oil pressure,
high coolant temperature,
low fuel level
Performance Data
1.50
4.73
1.25
3.79
2.84
1.89
Us Gal./Hr.
Liters/Hr.
Fuel Consumption Curve
5.68
Simultaneous Welding and Power
1.00
0.75
0.50
0.95
0.25
0.00
0.00
Idle
0
50
100
150
200
250
300
350
DC Weld Amperes at 100% Duty Cycle
4
400
Weld Amperes
Total Aux. Power Available (Watts)
25 A
10,000
75 A
10,000
125 A
10,000
175 A
9,000
225 A
7,500
300 A
4,500
350 A
1,000
Function Guide
1. Self-calibrating digital weld meters with
fault code indication display preset or
actual weld parameters.
2. Pushbutton main control knob used for
adjusting amperage/voltage, adjusting arc
control, and accessing the service menu.
3. LED process indicator. Front panel process
selections are illuminated with an LED that
identifies the active process. This enables
the selected weld process to be seen at a
distance from the power source.
7
8
9
1
10
2
11
3
12
4
13
5
4. Lift-Arc ™ TIG with Auto-Stop™ and
Auto-Crater.™
5. USB port allows software updates from a
USB drive. A summary file of recoded data
from the unit will be saved to a USB drive
that is inserted.
14
6
15
6. Weatherproof Lexan® nameplate is super
durable and resists cracking and fading.
7. Adjustable arc control adjusts DIG when
process control is in stick mode and adjusts
inductance when process control is in
FCAW or MIG mode. The amount of DIG
determines how much amperage (heat)
varies with stick arc length. Inductance
determines the “wetness” of the weld puddle.
8. Maintenance interval reminder. Yellow
and red indicator lights let an operator
know when the machine is approaching
and finally in need of routine maintenance.
9. Fuel indicator gauge. Low fuel shutdown
shuts engine off prior to running out of
fuel to prevent loss of fuel in the system,
and make restarts easy.
10. Engine coolant temperature gauge
displays coolant temperature. Engine stops
if temperature exceeds 230°F (110°C).
11. Glow plugs assist in cold weather starting.
12. Engine control switch is used to start the
engine and then select between auto idle
and high speed lock.
13. Standard 14-pin receptacle for simple
connection of remote controls and wire
feeders. Includes Auto Remote Sense™
which automatically switches from panel
to remote amperage/voltage (A/V) control
with remote connected. Eliminates
confusion of a panel/remote switch.
ARC START with Lift-Arc
™
Touch or scratch
Lift at any angle
Shielding
gas
Arc
Shielding
gas
• Reduces or eliminates sticking
• Reduces or eliminates electrode/
work contamination
• Low open-circuit voltage
Workpiece
ARC END with Auto-Stop
™
For Auto-Stop, lift up to terminate arc
While welding
Shielding
gas
Lift up
until arc
ends
Arc ends
without
flare
Move back
down to
maintain gas
coverage
Arc
• Eliminates need for a remote
control
• Maintains shielding gas coverage
• Eliminates tungsten and
workpiece contamination
• Eliminates unwanted arc strikes
outside the weld area
Workpiece
ARC END with Auto-Crater
While welding
Shielding
gas
Arc
™
To start Auto-Crater, press
momentary contact switch
Welding
current
ramps
down
Maintain
shielding
gas
coverage
• Maintains shielding gas coverage
• Eliminates tungsten and workpiece
contamination
• Auto-Crater time allows for
addition of filler
• Eliminates unwanted arc strikes
outside the weld area
Workpiece
14. 50 A, 120/240 V receptacle and 20 A, 120 V
GFCI receptacles with circuit breakers
Note: For matching 240 V plug, order 119172.
15. Weld output terminals
5
Genuine Miller Accessories
®
Female
Receptacle
MIG (GMAW) or Flux-cored (FCAW)
Full KVA Adapter Cord 300517 Field
NEMA 14-50P to NEMA 6-50R. Adapts engine
drive 120/240 V plug to common Millermatic®
and Spectrum® 240 V plug.
Full KVA Plug Kit
119172 Field
120/240 V, 50 A plug
(NEMA 14-50P) to fit full
KVA receptacle.
Engine Filter Kit 252782 Field
For Mitsubishi. Includes all filters required for
proper engine maintenance. Oil filter, primary
and secondary fuel filter, and primary air filter.
Spark Arrestor
(Muffler) Kit
300585 Field
Prevents particles
from leaving the
muffler that could
potentially start a
fire. Mandatory when operating on California
grasslands, brush, or forest-covered land, and in
all national forests. For other areas, check your
state and local laws. Meets U.S. Forest Service
Standard 5100-1B.
FA-1D Lockable Flame Arrestor
Fuel Cap 043947 Field
Fuel cap can be padlocked to
prevent vandalism. A built-in flame
arrestor prevents flames or sparks
from entering the fuel tank.
Protective Cover 195301 Field
Blue water-resistant cover with Miller logo
resists stains and mildew, and protects the
finish of your welder.
6
SuitCase® X-TREME™ 8VS Wire Feeder
951582
SuitCase® X-TREME™ 12VS Wire Feeder
951543
Lightweight, voltage-sensing wire feeders include
secondary contactor, gas valve, drive roll kit and
Bernard™ BTB Gun 300 A. See literature M/6.42.
SuitCase® 12RC Wire Feeder
951580
Lightweight and flexible
enough to run wires up to
.062-inch diameter. Includes
remote voltage control, drive
roll kit and Bernard™ BTB Gun
300 A. See literature M/6.5.
MIG (GMAW)/Flux-cored (FCAW) Guns
See Bernard™ literature SP-BTB for BTB
air-cooled MIG guns, and SP-DF for Dura-Flux™
self-shielded flux-cored guns.
Spoolmatic® 30A
Spool Gun 130831
Air-cooled, 200-amp,
one-pound spool gun
for aluminum and
stainless MIG. See literature M/1.73. Requires
WC-24 Control (137549).
XR™ Wire Feeders and Guns
Push-pull system designed to handle difficultto-feed soft alloy wires such as aluminum.
See literature M/1.7 through M/1.74.
AC TIG (GTAW) Welding
The Dynasty 210 power sources can be run off the
engine drive’s generator to provide two arcs with only
one engine.
Dynasty® 210 Series
For portable AC/DC TIG.
See literature AD/4.81.
Multiple Operator Welding
The XMT 350 FieldPro and CST 280 power sources
can be run off the engine drive’s generator to provide
two arcs with only one engine.
ArcReach® SuitCase® 8
951726 With Bernard™ BTB Gun 300 A
951727 With Bernard™ S-Gun™
951728 With Bernard™ Dura-Flux™ gun
ArcReach® SuitCase® 12
951729 With Bernard™ BTB Gun 300 A
951730 With Bernard™ S-Gun™
951731 With Bernard™ Dura-Flux™ gun
Portable feeder designed to run off of arc voltage.
When paired with an ArcReach power source,
provides remote control of the power source
without a control cord — saving time and money.
See literature M/6.55.
ArcReach® Smart
Feeder 951733
For use with ArcReach
models only (see page
2 for more information).
Includes drive rolls and
Bernard™ PipeWorx
300-15 MIG gun.
For MIG, FCAW, and
advanced RMD® and
pulse processes. See
literature M/6.55.
XMT® 350 FieldPro™
See literature DC/18.96.
CST ™ 280
See literature DC/29.55.
Genuine Miller Accessories (Continued)
®
Plasma Cutting
Stick/TIG Remote Controls
ArcReach® Stick/TIG
Remote 301325
When paired with
an ArcReach power
source, provides
remote control of
the power source
without a control
cord — saving time
and money. See literature AY/14.5.
Spectrum 375 X-TREME and 625 X-TREME shown.
Spectrum® 375 X-TREME™ 907529
See literature PC/9.2.
Spectrum® 625 X-TREME™ 907579
See literature PC/9.6.
Spectrum® 875 907583
See literature PC/9.8.
Wireless Remote Hand
Control 300430
For remote current, voltage
and contactor control.
Receiver plugs directly into
the 14-pin receptacle of
Miller machine. 300-foot
(91.4 m) operating range.
The Spectrum 375 X-TREME and 625 X-TREME
come complete with protective X-CASE™
(not shown).
Wireless Antenna Kit 300749
Recommended for improved reception.
RHC-14 Hand Control
242211020
Miniature hand control for
remote current, voltage and
contactor control. Dimensions:
4 x 4 x 3.25 in. (102 x 102 x 82 mm).
Includes 20-foot (6 m) cord and 14-pin plug.
Trailers and Hitches (Note: Trailers are shipped unassembled.)
RMS-14 On/Off Control 187208
Momentary-contact switch for contactor control.
Rubber-covered pushbutton dome switch
ideal for repetitive on-off applications. Includes
26.5-foot (8 m) cord and 14-pin plug.
RCC-14 Remote Contactor and Current Control
151086
East/west rotary-motion fingertip control
attaches to TIG torch using two hook-and-loop
fasteners. Includes 26.5-foot (8 m) cord and
14-pin plug.
PRHC-14 Hand Control
195511
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-foot (38 m) cord with plugs.
Extension Cables for 14-Pin Remote Controls
or 24 VAC Wire Feeders
242208025 25 ft. (7.6 m)
242208050 50 ft. (15.2 m)
242208080 80 ft. (24.4 m)
Mounting Specifications
F
Cable Tree 043826
Provides an area to
conveniently wrap weld cables
and extension cords.
HWY-Mid Frame Trailer 301438
1,424-pound (646 kg) capacity highway trailer
with welded steel tubing frame, heavy-duty
axle with roller bearing hubs and leaf-spring
suspension. Includes jack stand, fenders, lights,
and dual hitch with 2-inch (50 mm) ball hitch
and 3-inch (76 mm) lunette eye.
A
B
4 holes
Front Panel
C
D
E
A. 27.75 in. (705 mm)
B. 26.25 in. (667 mm)
C. 52.25 in. (1,327 mm)
D. 2 in. (51 mm)
E. 56 in. (1,422 mm)
F. .562 in. (14 mm) dia.
2-In-1 Document/
Fire Extinguisher Holder
301236
Stores documents and holds
a 5-pound fire extinguisher.
Note: Holder shown mounted
on trailer. Fire extinguisher
not included.
Height: 32 in. (813 mm)
Width: 26.25 in. (667 mm)
Depth: 56 in. (1,422 mm)
Trailer Specifications (Subject to change without notice.)
Model
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)
Dimensions
Net
Weight
HWY-Mid
Frame
1,605 lb.
(728 kg)
1,424 lb.
(646 kg)
1,424 lb.
(646 kg)
19.5 in.
(495 mm)
8 in.
(203 mm)
46 in.
(1,168 mm)
ST175/80D-13
Load Range C
Length: 101 in. (2,565 mm)
Width: 55 in. (1,397 mm)*
181 lb.
(82 kg)
*Width at outside of fenders.
7
Ordering Information
Equipment and Options
Stock No.
Description
907703001
907703
Mitsubishi. Blue with ArcReach remote control technology
Mitsubishi. Stainless steel with ArcReach remote control technology
Full KVA Adapter Cord
300517
Field
Full KVA Plug Kit
119172
120/240 V. Field
Engine Filter Kit
252782
Field. For Mitsubishi, includes air, oil and fuel filters
Spark Arrestor (Muffler) Kit
300585
Field
FA-1D Lockable Flame Arrestor Fuel Cap
043947
Field
Protective Cover
195301
Field
951582
With Bernard™ BTB Gun 300 A. See literature M/6.42
951543
With Bernard™ BTB Gun 300 A. See literature M/6.42
SuitCase 12RC
951580
With Bernard™ BTB Gun 300 A. See literature M/6.5
ArcReach® SuitCase® 8
951726
951727
951728
With Bernard™ BTB Gun 300 A. See literature M/6.55
With Bernard™ S-Gun™
With Bernard™ Dura-Flux™ gun
ArcReach® SuitCase® 12
951729
951730
951731
With Bernard™ BTB Gun 300 A. See literature M/6.55
With Bernard™ S-Gun™
With Bernard™ Dura-Flux™ gun
ArcReach® Smart Feeder
951733
MIG/FCAW/RMD®/pulse feeder with Bernard™ PipeWorx 300-15 MIG gun.
Tweco®-style connectors. See literature M/6.55
®
Big Blue 400 PipePro
Qty.
Field Accessories
MIG/Flux-cored Welding
SuitCase® X-TREME™ 8VS
®
™
SuitCase X-TREME 12VS
®
See Bernard™ literature SP-BTB and SP-DF
MIG (GMAW) and Flux-cored (FCAW) Guns
Spoolmatic® 30A Spool Gun
130831
Requires WC-24 Control. See literature M/1.73
WC-24 Control
137549
See literature M/1.73
XR™ Wire Feeder Control and Guns
See literature M/1.7 through M/1.74
TIG Welding
See page 6
Multiple Operator Welding
See page 6
Plasma Cutting
See page 7
Stick/TIG Remote Controls
ArcReach® Stick/TIG Remote
301325
Provides remote control of stick and TIG processes without a control cord
Wireless Remote Hand Control
300430
Hand control with wireless 300 ft. (91.4 m) operating range
Wireless Antenna Kit
300749
Recommended for improved reception
RHC-14 Hand Control
242211020
Hand control with 20 ft. (6 m) cord
RMS-14 On/Off Control
187208
Remote contactor control
RCC-14 Remote Contactor and Current Control
151086
Fingertip control
PRHC-14 Hand Control
195511
Hand control with 120 V GFCI receptacle, 125 ft. (38 m)
Extension Cables
See page 7
Trailers and Hitches
HWY-Mid Frame
301438
Trailer with lights, fenders and dual hitch. For highway use
Cable Tree
043826
Trailer-mounted cable holder
2-In-1 Document/Fire Extinguisher Holder
301236
Stores documents and holds a 5-pound fire extinguisher
Date:
Distributed by:
© 2017 Miller Electric Mfg. Co.
Total Quoted Price:
Price

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