Miller Electric Big 40 Diesel User Manual

Processes

CC and CC/CV Models

Stick (SMAW)
TIG (GTAW)
Air Carbon Arc (CAC-A)

Cutting and Gouging
(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)

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)

Heavy Industrial
Applications

Petro Chemical Piping
Structural Steel Work
Maintenance and Repair

Quick
Specs

Big 40®Diesel

Diesel Engine-Driven

Welder/Generator

Issued April 2008 • Index No. ED/8.5

Simplified control panel provides
easy set-up with fewer controls—
less training is required.

Standard GFCI receptacle required
on most job sites to protect
operators from electrical hazards.

CSA, IEC, and NEMA compliant for
welders. Degree of protection

provided by enclosure IP23.

Hot Start

™

provides positive Stick electrode
starts to make it easy to start all types of
electrodes, and works great for bead tie-ins.

Automatic idle saves fuel and prolongs
engine life along with reducing the
sound level.

Arc-Drive makes welding easy.
Automatically enhances Stick
welding, especially on pipe, by
focusing the arc and preventing
the electrode from going out.

The Power of Blue®.

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

Web Site

www.MillerWelds.com

International Headquarters

Phone: [phone]
USA FAX: [phone]
Canadian FAX: [phone]
International FAX: [phone]

CATERPILLAR industrial engine designed
to operate over 10,000 hours before the
first basic overhaul. Backed by worldwide
CAT support and service.

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

73.8 dB at 23 ft (98.7 Lwa) maximum
output. Improves work site communications.

Enclosed base and case protects
internal components from corrosive
environments and reduces sound levels.

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

The CATERPILLAR engine is warranted for 2 years by CATERPILLAR.

Quick and easy maintenance with
single-side access to oil level check,

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

Remote toolless oil drain that allows oil to
be drained without getting under the engine
and reduces the chance of oil spillage.

AC TIG weld aluminum with deluxe model.
The most AC weld output on any engine
drive. (High-frequency unit required.)

More welding amperage!

400 amps at 100% Duty Cycle
450 amps at 60% Duty Cycle
500 amps at 40% Duty Cycle

Engine gauges indicate engine oil
pressure, and coolant temperature
(standard on all models).

CC/CV Models: The Vault — ultimate
control board reliability. See page 4.

NEW!

Meter maintenance displays.

• Hour meter function

• Oil change interval

• High coolant temperature and
low oil pressure shutdowns

• Low fuel shutdown — engine
shuts downs before system runs
out of fuel, making restarts easy.

Accu-Rated

™

– Not Inflated

Generator Power

Improved!

Maintenance Displays!

2

Big 40®Diesel CC Control Panel

Welding
Mode

CC/DC

Big 40®Diesel CC Specifications

(Subject to change without notice.)

Max. Open­Circuit Voltage

95

Weld Output
Range

55 – 500 A

Weld Output Rated
at 104˚F (40˚C)

400 A at 36 VDC (14.4 kW),
100% Duty Cycle

450 A at 38 VDC (17.1 kW),
60% Duty Cycle

500 A at 30 VDC (15 kW),
40% Duty Cycle

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

Peak: 5500 watts
Continuous: 4000 watts,

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

Net Weight
(without fuel)**

1540 lb (697 kg)

Dimensions*

H: 43 in (1092 mm)
W: 28-1/2 in (724 mm)
D: 64-7/16 in (1637 mm)

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 Performance Data

100

80

60

40

20

0

0 100 200 300 400 500 600 700 800 900 1000

DC AMPERES

DC VOLTS

Ranges

170 – 365

230 – Max

110 – 225

55 – 85

70 – 130

0.00

0.25

0.50

0.75

1.00

1.25

1.50

1.75

2.00

0 50 100 150 200 250 300 350 400

DC WELD AMPERES

AT 100% DUTY CYCLE

US Gal./Hr.

0.00

0.95

1.89

2.84

3.79

4.73

5.68

6.62

7.57

US Liters/Hr.

IDLE

CC/DC VOLT/AMP CURVES FUEL CONSUMPTION CURVE

4 kW

5.5 kW

302520151050

6050403020100

AC AMPERES IN 240 V MODE

AC AMPERES IN 120 V MODE

50

0

100

150

200

250

300

AC VOLTS

0

25

50

75

100

150

125

GENERATOR POWER CURVE

Engine
Brand

CATERPILLAR

Tier III,
C2.2 Diesel

HP

32.6

Type

Four-cylinder,
industrial,
liquid-cooled
diesel

Engine
Speeds

Run: 1850 RPM
Idle: 1250 RPM

Fuel
Capacity

25 gal
(95 L)

Coolant
Capacity

9 qt
(8.5 L)

Automatic Engine
Shutdown

Oil Pressure
Coolant Temperature

Oil
Capacity

9 qt
(8.5 L)

Features

Tier III, EPA-certified, indirect-injected,
liquid-cooled diesel engine. Right-side
service access with service intervals of
500 hours for oil and filters.

Engine Specifications (Subject to change without notice.)

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. DC Ammeter*

2. DC Voltmeter*

3. Amperage Adjust Control

4. Amperage Range Switch

5. Amperage Adjust Switch and

Remote Amperage Adjust Receptacle

6. Stick/TIG Selector Switch

7. 120 VAC, 20 A GFCI Duplex Receptacle

8. 240 VAC, 30 A TwistLock Receptacle

(NEMA L6-30)

9. Fuel Gauge/Hour Meter/Oil Change Interval/

Engine Shutdown Indicator

10. Engine Oil Pressure Gauge

11. Battery Voltmeter*

12. Engine Coolant Temperature Gauge

13. Engine Control Switch

14. Starting Aid Switch

15. Polarity Switch*

*Optional on select models.

1

2
3
4

5
6

9
10
11

12

13
14

7

8

15

3

Big 40®Diesel CC/CV Control Panel

W

elding

Mode

CC/DC

CV/DC

CC/AC
(Deluxe
Model)

Big 40®Diesel CC/CV Specifications

(Subject to change without notice.)

Max. Open­Circuit Voltage

95

56

65

W

eld Output

Range

20 – 550 A

14 – 40 V

15 – 375 A

Weld Output Rated
at 104˚F (40˚C)

400 A at 36 VDC (14.4 kW),
100% Duty Cycle

450 A at 38 VDC (17.1 kW),
60% Duty Cycle

500 A at 34 VDC (17 kw),
40% Duty Cycle

300 A at 32 VAC (9.6 kW),
100% Duty Cycle

335 A at 33 V (11.1 kW),
60% Duty Cycle

375 A at 35 V (13.1 kW),
40% Duty Cycle

Generator Power Output Rated
Peak: 5000 watts

Continuous: 4000 watts,

34/17 A,

120/240 VAC, 60 Hz while welding

Deluxe Model Additional Power Plant:

1-phase, 12 kW, 50 A, 120/240 VAC, 60 Hz; or
3-phase, 15 kW, 36 A, 240 VAC, 60 Hz while

not welding

Net Weight
(without fuel)**

1545 lb
(701 kg)

Dimensions*

H: 43 in

(1092 mm)

W: 28-1/2 in

(724 mm)

D: 64-7/16 in

(1637 mm)

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.

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 amper age 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
con ditions 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.

Big 40®Diesel CC/CV Performance Data

0 100 200 300 400 500

Ranges

35 – 250

60 – 365

25 – 155
15 – 75

DC AMPERES

20

0

40

60

80

100

DC VOLTS

0

20

40

60

80

100

0 50 100 150 200 250 300 350 400450 500

Ranges

55 – 350
35 – 205
25 – 105
15 – 45

AC AMPERES

AC VOLTS

CC/CV VOLT/AMP CURVES

STICK MODE

CC/CV VOLT/AMP CURVES

TIG MODE

CC/CV VOLT/AMP CURVES

AC TIG MODE

CC/CV VOLT/AMP CURVES

MIG MODE

1. DC Ammeter*

2. DC Voltmeter*

3. Amperage/Voltage Adjust Control

4. Ampere Range Switch

5. Amperage/Voltage Adjust Switch and Remote
Amperage/Voltage Adjust Receptacle

6. Process/Contactor Selector Switch

7. 120 VAC, 20 A GFCI Duplex Receptacle

8. 240 VAC, 30A TwistLock Receptacle
(NEMA L6-30)

9. Fuel Gauge/Hour Meter/Oil Change Interval/
Engine Shutdown Indicator

10. Engine Oil Pressure Gauge

11. Battery Voltmeter*

12. Engine Coolant Temperature Gauge

13. Engine Control Switch

14. Starting Aid Switch

15. 3-Phase Power Generator Option*

16. Strain Relief*

17. 50 A, 3-Phase Circuit Breaker

18. 50 A, 120/240 V Receptacle
(NEMA 14-50)*

19. AC/DC Polarity Switch*

*Optional on select models.

1

2
3

4

5
6

5

7

8

9
10
11
12

13

Process/Contactor Selector Switch

14

15
16
17

18

19

100

80

60

40

DC VOLTS

20

0

0 100 200 300 400 500 600 700 800 900 1000

DC AMPERES

Ranges

155 – 450
115 – 320

75 – 195
40 – 90

100

Max

80

60

40

DC VOLTS

20

0

0 100 200 300 400 500 600 700 800 9001000

MAX

MIN

DC AMPERES