Miller Electric CC DC Stick 55500 A, FCAW 1440 V, Big 40, DC-TIG 55500 A User Manual

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Big 40® Diesel

 

 

Heavy Industrial

Processes

 

 

Applications

CC and CC/CV Models

 

 

Petro Chemical Piping

Stick (SMAW)

Quick

Structural Steel Work

TIG (GTAW)

Maintenance and Repair

Air Carbon Arc (CAC-A)

 

Cutting and Gouging

Specs

 

(Rated) 5/16 (7.9 mm) carbons

 

(Capable) 3/8 (9.5 mm) carbons

 

 

 

Stud Welding

 

 

 

CC/CV Model Only

 

 

 

MIG (GMAW)

 

 

 

Flux Cored (FCAW)

 

 

 

AC TIG (Deluxe Model)

 

 

 

 

Issued October 2008 • Index No. ED/8.5

Diesel Engine-Driven

Welder/Generator

Output Range

CC:

DC Stick 55 – 500 A

DC/TIG 55 – 500 A

CC/CV:

DC Stick 40 – 550 A

DC/TIG 20 – 350 A

 

AC TIG 15 – 375 A

MIG/FCAW 14 – 40 V

Generator Output Rated at 104˚F (40˚C)

5500 Watts Peak — 4000 Watts Continuous 15,000 Watts 3-Phase / 12,000 Watts 1-Phase (Deluxe Model)

Accu-Rated– Not Inflated

Generator Power

The Power of Blue.

to operate over 10,000 hours before the

®

CATERPILLAR industrial engine designed

 

AC TIG weld aluminum with deluxe model.

first basic overhaul. Backed by worldwide

CAT support and service.

The most AC weld output on any engine

 

NEW! Meter maintenance displays.

drive. (High-frequency unit required.)

 

Silenced — only 65 dB (90 Lwa) at idle.

 

Hour meter function

 

Oil change interval

73.8 dB at 23 ft (98.7 Lwa) maximum

Maintenance Displays!

• High coolant temperature and

output. Improves work site communications.

 

low oil pressure shutdowns

 

 

Automatic idle saves fuel and prolongs

 

• Low fuel shutdown — engine

 

 

shuts downs before system runs

engine life along with reducing the

 

 

 

 

out of fuel, making restarts easy.

sound level.

 

 

 

 

 

Quick and easy maintenance with

 

Simplified control panel provides

single-side access to oil level check,

 

easy set-up with fewer controls—

oil fill, oil filter, fuel filter and air cleaner.

 

less training is required.

Enclosed base and case protects

 

More welding amperage!

internal components from corrosive

 

400 amps at 100% Duty Cycle

environments and reduces sound levels.

 

450 amps at 60% Duty Cycle

Remote toolless oil drain that allows oil to

 

500 amps at 40% Duty Cycle

 

Engine gauges indicate engine oil

be drained without getting under the engine

 

and reduces the chance of oil spillage.

 

pressure, and coolant temperature

Hot Startprovides positive Stick electrode

 

(standard on all models).

 

Arc-Drive makes welding easy.

starts to make it easy to start all types of

 

electrodes, and works great for bead tie-ins.

 

Automatically enhances Stick

 

 

welding, especially on pipe, by

 

 

focusing the arc and preventing

 

 

the electrode from going out.

 

 

Standard GFCI receptacle required

 

 

on most job sites to protect

 

 

operators from electrical hazards.

 

 

CSA, IEC, and NEMA compliant for

 

 

welders. Degree of protection

CC/CV Models: The Vault — ultimate

 

provided by enclosure IP23.

control board reliability. See page 4.

 

 

 

Welder/generator is warranted for 3 years, parts and labor.

The CATERPILLAR engine is warranted for 2 years by CATERPILLAR.

Miller Electric Mfg. Co.

International Headquarters

Web Site

An Illinois Tool Works Company

Phone: 920-735-4505

www.MillerWelds.com

1635 West Spencer Street

USA FAX: 920-735-4134

 

Appleton, WI 54914 USA

Canadian FAX: 920-735-4169

 

 

International FAX: 920-735-4125

 

Big 40® Diesel CC Specifications (Subject to change without notice.)

Welding

Weld Output

Weld Output Rated

Max. Open-

Generator Output Rated

 

Net Weight

Mode

Range

at 104˚F (40˚C)

Circuit Voltage

at 104˚F (40˚C)

Dimensions*

(without fuel)**

CC/DC

55 – 500 A

400

A at 36

VDC (14.4 kW),

95

Peak: 5500 watts

H: 43 in (1092 mm)

1540 lb (697 kg)

 

 

100% Duty Cycle

 

Continuous: 4000 watts,

W: 28-1/2 in (724 mm)

 

 

 

450

A at 38

VDC (17.1 kW),

 

34/17 A, 120/ 240 VAC, 60 Hz

D: 64-7/16 in (1637 mm)

 

 

 

60% Duty Cycle

 

while welding

 

 

 

 

500

A at 30

VDC (15 kW),

 

 

 

 

 

 

40% Duty Cycle

 

 

 

 

 

 

 

 

 

 

 

 

 

NEMA EWI (ANSI C87.1) Class (1) output ratings. *Additional 7 in (178 mm) to top of exhaust. **Additional 190 lb (86 kg) when fuel tank is full.

Engine Specifications (Subject to change without notice.)

Engine

 

 

 

Engine

Fuel

Oil

Coolant

Automatic Engine

Brand

Features

HP

Type

Speeds

Capacity

Capacity

Capacity

Shutdown

CATERPILLAR

Tier IVi, EPA-certified, indirect-injected,

32.6

Four-cylinder,

Run: 1850 RPM

25 gal

9 qt

9 qt

Oil Pressure

Tier IVi,

liquid-cooled diesel engine. Right-side

 

industrial,

Idle: 1250 RPM

(95 L)

(8.5 L)

(8.5 L)

Coolant Temperature

C2.2 Diesel

service access with service intervals of

 

liquid-cooled

 

 

 

 

 

 

500 hours for oil and filters.

 

diesel

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Big 40® Diesel CC Control Panel

Additional Features

Proven, rugged rheostat control technology that has been in Miller engine drives for over 60 years. Contains no printed control boards.

Provisions are provided to plug a

RHC3GD34A remote control that will allow precise adjustment of amperage without walking back to the machine.

1

9

2

10

3

11

4

12

5

13

14

6

 

1.DC Ammeter*

2.DC Voltmeter*

3.Amperage Adjust Control

4.Amperage Range Switch

5.Amperage Adjust Switch and Remote Amperage Adjust Receptacle

7

8

15

6.

Stick/TIG Selector Switch

10. Engine Oil Pressure Gauge

7.

120 VAC, 20 A GFCI Duplex Receptacle

11. Battery Voltmeter*

8.

240 VAC, 30 A TwistLock Receptacle

12.

Engine Coolant Temperature Gauge

 

(NEMA L6-30)

13.

Engine Control Switch

9.

Fuel Gauge/Hour Meter/Oil Change Interval/

14.

Starting Aid Switch

 

Engine Shutdown Indicator

15.

Polarity Switch*

 

 

*Optional on select models.

Big 40® Diesel CC Performance Data

 

 

 

 

CC/DC VOLT/AMP CURVES

 

 

100

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Ranges

 

80

 

 

 

 

 

 

 

 

230

– Max

VOLTS

 

 

 

 

 

 

 

 

 

170

– 365

60

 

 

 

 

 

 

 

 

110

– 225

 

 

 

 

 

 

 

 

70

– 130

 

 

 

 

 

 

 

 

 

55

– 85

 

 

 

 

 

 

 

 

 

 

 

 

DC

40

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

20

 

 

 

 

 

 

 

 

 

 

 

 

0

0

100

200

300

400

500

600

700

800

900 1000

DC AMPERES

GENERATOR POWER CURVE

 

150

300

 

 

 

 

 

 

 

 

125

250

 

 

 

4 kW

 

5.5 kW

 

VOLTS

100

200

 

 

 

 

 

 

 

75 150

 

 

 

 

 

 

 

AC

50

100

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

25

50

 

 

 

 

 

 

 

 

0

0

0

5

10

15

20

25

30

AC AMPERES IN 240 V MODE

0

10

20

30

40

50

60

AC AMPERES IN 120 V MODE

FUEL CONSUMPTION CURVE

7.57

2.00

 

 

 

 

 

 

 

 

 

6.62

1.75

 

 

 

 

 

 

 

 

 

5.68

1.50

 

 

 

 

 

 

 

 

 

4.73

1.25

 

 

 

 

 

 

 

 

 

3.79

1.00

 

 

 

 

 

 

 

 

 

2.84

0.75

 

 

 

 

 

 

 

 

 

1.89

0.50

 

 

 

 

 

 

 

 

 

0.95

0.25

 

IDLE

 

 

 

 

 

 

 

0.00

0.00

0

50

100

150

200

250

300

350

400

US Liters/Hr.

US Gal./Hr.

 

 

DC WELD AMPERES

 

 

 

 

AT 100% DUTY CYCLE

 

 

 

 

 

 

 

 

 

 

 

2

Miller Electric CC DC Stick 55500 A, FCAW 1440 V, Big 40, DC-TIG 55500 A User Manual

Big 40® Diesel CC/CV Specifications (Subject to change without notice.)

Welding

Weld Output

Weld Output Rated

Max. Open-

 

 

Net Weight

Mode

Range

at 104˚F (40˚C)

Circuit Voltage

Generator Power Output Rated

Dimensions*

(without fuel)**

 

 

 

 

 

 

 

 

CC/DC

20 – 550 A

400

A at 36 VDC (14.4 kW),

95

Peak: 5000 watts

H: 43 in

1545 lb

 

 

100% Duty Cycle

 

Continuous: 4000 watts, 34/17 A,

(1092 mm)

(701 kg)

CV/DC

14 – 40 V

450

A at 38 VDC (17.1 kW),

56

120/240 VAC, 60 Hz while welding

W: 28-1/2 in

 

 

 

60% Duty Cycle

 

Deluxe Model Additional Power Plant:

(724 mm)

 

 

 

500

A at 34 VDC (17 kw),

 

1-phase, 12 kW, 50 A, 120/240 VAC, 60 Hz; or

D: 64-7/16 in

 

 

 

40% Duty Cycle

 

3-phase, 15 kW, 36 A, 240 VAC, 60 Hz while

(1637 mm)

 

 

 

 

 

 

not welding

 

 

CC/AC

15 – 375 A

300

A at 32 VAC (9.6 kW),

65

 

 

 

 

 

(Deluxe

 

100% Duty Cycle

 

 

 

 

Model)

 

335

A at 33 V (11.1 kW),

 

 

 

 

 

 

60% Duty Cycle

 

 

 

 

 

 

375

A at 35 V (13.1 kW),

 

 

 

 

 

 

40% Duty Cycle

 

 

 

 

 

 

 

 

 

 

 

NEMA EWI (ANSI C87.1) Class (1) output ratings. *Additional 7 in (178 mm) to top of exhaust. **Additional 190 lb (86 kg) when fuel tank is full.

 

Big 40® Diesel CC/CV Control Panel

 

 

 

Additional Features

A multi-colored process selector control allows quick and easy process changes without having to use multiple switches.

Heavy-Duty Design — The Vault design provides enhanced arc characteristics that include more dig in the Stick mode with smoother and lower amperage in the TIG mode. Along with the superior welding performance, the Vault provides the ultimate reliability in the harshest of environments.

A hermetically-sealed vault protects Miller control boards from dust, moisture, and tough environmental elements. Extreme conditions will not cause the output to change, eliminating the need to periodically turn up the heat.

15,000 watt generator option for stand-by power generation adds 15 kW, three-phase, 240 volt power to CC/CV units. 12 kW, 120/240 volt, single-phase power from a 50 amp receptacle while not welding.

1

2

3

4

5

6

5

7

8

9

10

11

12

13

14

Process/Contactor Selector Switch

 

15

16 17

18

19

1.

DC Ammeter*

10.

Engine Oil Pressure Gauge

2.

DC Voltmeter*

11.

Battery Voltmeter*

3.

Amperage/Voltage Adjust Control

12.

Engine Coolant Temperature Gauge

4.

Ampere Range Switch

13.

Engine Control Switch

5.

Amperage/Voltage Adjust Switch and Remote

14.

Starting Aid Switch

 

Amperage/Voltage Adjust Receptacle

15.

3-Phase Power Generator Option*

6.

Process/Contactor Selector Switch

16.

Strain Relief*

7.

120 VAC, 20 A GFCI Duplex Receptacle

17.

50 A, 3-Phase Circuit Breaker

8.

240 VAC, 30A TwistLock Receptacle

18.

50 A, 120/240 V Receptacle

 

(NEMA L6-30)

 

(NEMA 14-50)*

9.

Fuel Gauge/Hour Meter/Oil Change Interval/

19.

AC/DC Polarity Switch*

 

Engine Shutdown Indicator

*Optional on select models.

Big 40® Diesel CC/CV Performance Data

CC/CV VOLT/AMP CURVES

CC/CV VOLT/AMP CURVES

STICK MODE

MIG MODE

 

100

 

 

 

 

 

 

 

 

 

 

100

 

 

 

 

 

 

 

 

 

 

 

 

 

Ranges

 

 

 

 

 

 

 

80

 

 

 

 

 

 

 

 

Max

 

80

 

 

 

 

 

 

 

 

 

 

 

 

 

155

– 450

DC VOLTS

 

 

 

 

 

DC VOLTS

60

 

 

 

 

 

 

 

115 – 320

60

 

 

 

 

 

 

 

 

 

 

 

75

– 195

 

 

 

 

40

 

 

 

 

 

 

 

40

– 90

40

 

MAX

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

20

 

 

 

 

 

 

 

 

 

20

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MIN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

0

100

200

300

400

500

600

700

800

900 1000

 

0

100

200 300 400

500 600 700 800

900 1000

DC AMPERES

DC AMPERES

CC/CV VOLT/AMP CURVES

CC/CV VOLT/AMP CURVES

TIG MODE

AC TIG MODE

 

100

 

 

 

 

 

 

100

 

 

 

 

 

 

 

Ranges

 

 

80

Ranges

 

80

 

 

 

60 – 365

 

 

55

– 350

 

 

 

 

 

35 – 250

 

VOLTS

 

35

– 205

VOLTS

60

 

 

 

25 – 155

 

60

25

– 105

 

 

 

15 – 75

 

15

– 45

40

 

 

 

 

 

40

 

 

DC

 

 

 

 

 

AC

 

 

 

 

 

 

 

 

20

 

 

 

20

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

 

0

 

 

 

0

100

200

300

400

500

 

0

50 100 150 200 250 300 350 400

450 500

DC AMPERES

AC AMPERES

3

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