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BigBlue 350PipePro Welder/AC Generator Diesel Engine-Driven Flipbook PDF
2 Simple-to-set controls require no elaborate procedure—just select process and weld! Infinite arc control allows the ar
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Issued Dec. 2015 • Index No. ED/5.4
Big Blue 350 PipePro ®
®
Heavy Industrial Applications
Quick Specs
Processes
Output Range
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
Pipe welding Mechanical contractor
Diesel Engine-Driven Welder/AC Generator DC stick 20–400 A FCAW/MIG 14–40 V DC TIG 20–400 A
Generator Output Rated at 104°F (40°C) 12,000 watts peak, 10,000 watts continuous
*Available only on Big Blue 350 PipePro SF models
Big Blue 350 PipePro Designed exclusively for transmission pipeline work, the Big Blue 350 PipePro offers stick as well as MIG/flux-cored welding capabilities to meet high-strength steel requirements and is ideal for the most demanding pipeline jobs.
NEW! Big Blue® 350 PipePro SF Improve productivity and quality with advanced RMD® and pulsed MIG processes with the FieldPro Smart Feeder.
Big Blue 350 PipePro (USA model) The vault — ultimate control board reliability. See page 5. Superior arc performance • Adjustable arc control • Adaptive Hot Start ™ (stick) • FCAW/MIG arc performance • Lift-Arc™ TIG with Auto-Stop™
Auto Remote Sense™ (ARS) detects if a remote control is plugged into the 14-pin receptacle and eliminates confusion of a remote/panel switch. Low OCV stick (VRD) reduces the open-circuit voltage to 15 volts when the welding power source is not in use, increasing operator safety without compromising arc starts.
Big Blue 350 PipePro SF (USA model)
Caterpillar C1.5T three-cylinder diesel
Mitsubishi S4L2 four-cylinder diesel Heavy-duty low-speed industrial engines are designed to operate over 10,000 hours before the first basic overhaul. Backed by worldwide support and service.
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 MillerWelds.com
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
Models Overview Base model LINE-X® cover is workbench tough and provides superior impact, corrosion and abrasion protection.
Simple-to-set controls require no elaborate procedure — just select process and weld! Infinite arc control allows the arc characteristics to be changed for specific applications in stick and MIG. HD powder coat with zinc-rich primer protects sheet metal from rust and corrosion.
Engine coolant temperature gauge and 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 Standard features include digital preset weld meters, output contactor control, automatic idle and 120-volt block heater.
NEW! SF model additional features Advanced RMD® and pulsed MIG processes are now available in an engine driven welder/generator. Discover increased productivity, quality, and improved efficiency in field welding with the new Big Blue 350 PipePro SF with FieldPro™ Smart Feeder.
FieldPro Smart Feeder FieldPro Smart Feeder delivers excellent RMD® and pulsed MIG welding up to 200 feet away from the power source with no control cables — twice the distance previously possible. RMD and pulsed MIG processes help reduce weld failures and eliminate backing gas on some stainless and chrome-moly pipe-welding applications. Durable design reduces downtime. Impact-resistant case and the elimination of feeder control cables provide a solid solution to last in harsh environments. Full remote control at the weld joint. Simply connect standard weld cables in-line with the FieldPro Smart Feeder and you’re ready to go!
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Simple-to-set controls have integrated support for Smart Feeder, simply turn the knob to either MIG VS or FCAW VS for optimal performance. Stainless steel appearance package provides additional exterior protection to withstand corrosive environments. Big Blue 350 PipePro SF (#907 478 002 with CAT Turbo) or (#907 428 002 with Mitsubishi) shown with FieldPro Smart Feeder (#300 935) and Bernard™ PipeWorx 300 MIG gun (#195 400). Items sold separately.
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)
CC/DC (TIG)
20–400 A
85 VDC 15 VDC*
12,000 watts peak, 10,000 watts continuous
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
Sound Levels at Rated Output, 23 ft. (7 m)
Dimensions
Weight (without fuel)**
CAT Idle: 65 dB (90 Lwa) Weld: 71.2 dB (96 Lwa) Mitsubishi Idle: 68.7 dB (93 Lwa) Weld: 72.1 dB (97 Lwa)
H: 32 in. (813 mm) W: 26.25 in. (667 mm) D: 56 in. (1,422 mm)
CAT Net: 1,063 lb. (482 kg) Ship: 1,113 lb. (505 kg) Mitsubishi Net: 1,018 lb. (462 kg) Ship: 1,068 lb. (484 kg)
*Sense voltage for stick and Lift-Arc™ TIG. **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.
CAT powered International model is
approved.
Engine Specifications (Engines warranted separately by the engine manufacturer.) Engine Brand
Features
HP
Type
Engine Speeds
Capacities
Automatic Engine Shutdown
Caterpillar C1.5T
EPA Tier 4 Final compliant
24.7
Three-cylinder, liquid-cooled industrial diesel
Weld: 1,800 rpm Idle: 1,500 rpm
Fuel: 11.5 gal. (43.5 L) Oil: 5.9 qt. (5.6 L) Coolant: 7.2 qt. (6.8 L)
Low oil pressure, high coolant temperature, low fuel level
Mitsubishi S4L2
EPA Tier 4 Final compliant
24.7
Four-cylinder, liquid-cooled industrial diesel
Weld: 1,800 rpm Idle: 1,500 rpm
Fuel: 11.5 gal. (43.5 L) Oil: 5.8 qt. (5.5 L) Coolant: 10 qt. (9.5 L)
Performance Data Simultaneous Welding And Power
1.50
4.73
1.25
Weld Amperes
Total Aux. Power Available (Watts)
120 V
240 V
1.00
25 A
10,000
83.3
41.6
0.75
75 A
10,000
83.3
41.6
125 A
10,000
83.3
41.6
175 A
9,000
75
37.5
225 A
7,500
62.5
31.3
300 A
4,500
37.5
18.8
350 A
1,000
8.3
4.2
3.79 2.84 1.89 0.95 0.00
Us Gal./Hr.
Liters/Hr.
Fuel Consumption Curve 5.68
0.50
Idle
0.25 0.00 0
50
100
150
200
250
300
350
DC Weld Amperes at 100% Duty Cycle
400
3
Function Guide 1. Self-calibrating digital weld meters with fault code indication display preset or actual weld parameters. 2. Weatherproof Lexan® nameplate is super durable and resists cracking and fading. Color coded for ease of operation. 3. Hot Start ™ provides positive stick electrode starts making it easy to start all types of electrodes and it also works great for bead tie-ins. 4. Smart Feeder setting (SF model only). Recommended for optimal Smart Feeder operation.
1
9
2
10
3 4
11
5
12
6
13
7
8 120/240 V, 50 A receptacle
120 V, 20 A GFCI receptacles
Circuit breakers
5. Great FCAW/MIG performance and arc starts make the Big Blue® 350 PipePro arc the best in its class. Easy to run all wires from .023-inch solid wires to large-diameter 5/64-inch flux-cored wires. 6. Lift-Arc ™ TIG with Auto-Stop™
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USA model
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. Standard 14-pin receptacle for simple connection of remote controls and wire feeders. It features 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. 9. Engine coolant temperature gauge displays coolant temperature. Engine stops if temperature exceeds 230°F (110°C). 10. Meter maintenance display shows fuel level, engine hours, oil change interval and high temp/low pressure/low fuel shutdown information. 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. 11. Glow plugs assist in cold weather starting.
240 V, 16 A AC receptacle
120 V, 16 A AC receptacle
ARC START with Lift-Arc
™
Touch or scratch
Lift at any angle
• Reduces or eliminates sticking • Reduces or eliminates electrode/ work contamination • Low open-circuit voltage
Shielding gas Arc
Shielding gas
Workpiece
ARC END with Auto-Stop
™
For Auto-Stop, lift up to terminate arc
While welding
Shielding gas Arc
14. Weld output terminals Workpiece
4
120 V, 20 A AC receptacle with ground fault
International model receptacles
12. Engine control switch is used to start the engine and then select between auto idle and high speed lock. 13. Amperage/voltage adjust control
Earth leakage circuit breaker
Lift up until arc ends
Arc ends without flare
Move back down to maintain gas coverage
• Eliminates need for a remote control • Maintains shielding gas coverage • Eliminates tungsten and workpiece contamination • Eliminates unwanted arc strikes outside the weld area
What Makes Miller Industrial Engine Drives So ®
Superior circuit board design Our 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.
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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 jobsite.
“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 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.
• Humidity and corrosion. Inside our 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 industrial engine drives are tested to ensure performance in scorching heat. All Miller engine-driven machines are weld rated at 104 degrees Fahrenheit, but actual tests are conducted up to 122 degrees Fahrenheit 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 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 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 story, and many others demonstrating our superior reliability, at MillerWelds.com.
“The Miller 350 PipePro makes my job easier every day. It runs a 3/16 electrode downhill smoother and keeps it lit better than any machine I’ve used.” Jerry Morley, Gas Field Specialists Inc, Plumbers and Steamfitters #267
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Genuine Miller Accessories ®
Female Receptacle
MIG (GMAW) or Flux-Cored (FCAW)
Full KVA Adapter Cord #300 517 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 #119 172 Field 120/240 V, 50 A plug (NEMA 14-50P) to fit full KVA receptacle. International Plugs #255 419 Field 1-phase,120 V, 16 A plug #255 416 Field 1-phase, 240 V, 16 A plug
Engine Filter Kits #246 987 Field. For CAT #252 782 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 #300 585 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 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 #043 947 Field Fuel cap can be padlocked to prevent vandalism. A built-in flame arrestor prevents flames or sparks from entering the fuel tank.
PipeWorx Memory Cards For use with FieldPro Smart Feeder only. SuitCase® X-TREME™ 8VS Wire Feeder #951 583 With Bernard™ BTB Gun 300 A SuitCase® X-TREME™ 12VS Wire Feeder #951 544 With Bernard™ Dura-Flux™ gun Lightweight, voltage-sensing wire feeders include secondary contactor, gas valve, drive roll kit and gun. See Lit. Index No. M/6.42. SuitCase® 12RC Wire Feeder #951 580 Lightweight and flexible enough to run a variety of wires up to .062-inch diameter. Includes remote voltage control, drive roll kit and Bernard™ BTB Gun 300 A. See Lit. Index No. M/6.5.
#301 230 System Software For free download, visit MillerWelds.com #300 557 Calibration Used to calibrate the PipeWorx System. For free download, visit MillerWelds.com #300 744 Inconel Pulsed MIG, .045-inch diameter wire, 100% argon #300 460 Range Locks Provides ability to set nominal parameter values and ranges for wire feed processes. #300 667 Accu-Power™ Displays instantaneous power during welding to meet the new ASME requirement for calculating heat input on complex waveform processes (RMD® and pulsed MIG). #301 035 Trigger Select/Hold Option Enables trigger select while welding to change processes and parameters without stopping.
TIG (GTAW) Welding FieldPro™ Smart Feeder #300 935 For use with Big Blue 350 PipePro SF model only. See page 2 for more information.
Dynasty® 210 Series #907 685, #907 686 For premium portable AC/DC TIG arc quality. See Lit. Index No. AD/4.81. HF-251D-1 #042 388 115 V. High-frequency arc starter and stabilizer. See Accessory Lit. Index No. AY/5.0.
Protective Cover #195 301 Field Blue water-resistant cover with Miller logo resists stains and mildew, and protects the finish of your welder.
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Genuine Miller Accessories (Continued) ®
Plasma Cutting
Remote Controls Wireless Remote Hand Control #300 430 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. Requires Wireless Antenna Kit #300 749.
Spectrum 375 X-TREME and 625 X-TREME shown. ®
Wireless Antenna Kit #300 749 Required for Pro Series engine drives. Optional on other compatible Miller products where improved reception is desired.
™
Spectrum 375 X-TREME #907 529 See Lit. Index No. PC/9.2. Spectrum® 625 X-TREME™ #907 579 See Lit. Index No. PC/9.6. Spectrum® 875 #907 583 See Lit. Index No. PC/9.8.
PRHC-14 Hand Control #195 511 Complete current or voltage control brings 120 V GFCI power to work area in a single cord. Housed in durable aluminum case and includes 125-foot (38 m) cord with plugs. Extension Cables for 14-Pin Remote Controls or 24 VAC Wire Feeders #242 208 025 25 ft. (7.6 m) #242 208 050 50 ft. (15.2 m) #242 208 080 80 ft. (24.4 m)
The Spectrum 375 X-TREME and 625 X-TREME come complete with protective X-CASE™ (not shown).
Trailers and Hitches (Note: Trailers are shipped unassembled.)
Mounting Specifications
Cable Tree #043 826 Provides an area to conveniently wrap weld cables and extension cords.
F
A
HWY-224 Trailer #043 805 A 2,650-pound (1,202 kg) capacity trailer for highway use. Welded steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-spring suspension. Includes jack stand, 2-inch (50 mm) ball hitch, fenders and lights.
B
4 holes
Front Panel
C D E
Dual Hitch #300 831 2-inch (50 mm) ball hitch and 3-inch (76 mm) lunette eye in one reversible assembly.
A. 27.75 in. (705 mm) B. 26.25 in. (667 mm) C. 52 in. (1,321 mm) D. 2 in. (51 mm) E. 56 in. (1,422 mm) F. .562 in. (14 mm) diameter 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 HWY-224
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)
3,500 lb. (1,588 kg)
2,960 lb. (1,343 kg)
2,650 lb. (1,202 kg)
18.5 in. (470 mm)
7.25 in. (184 mm)
52 in. (1,321 mm)
B78-13
Dimensions
Net Weight
Length: 105 in. (2,667 mm) Width: 59.5 in. (1,511 mm)*
320 lb. (145 kg)
*Width at outside of fenders.
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Ordering Information Equipment and Options
Stock No.
Description
Big Blue 350 PipePro
#907 478 #907 428
Base USA model with CAT Turbo Base USA model with Mitsubishi
Big Blue® 350 PipePro® SF
#907 478 002 #907 428 002
Smart Feeder compatible model with CAT Turbo and stainless steel package Smart Feeder compatible model with Mitsubishi and stainless steel package
Big Blue® 350X PipePro®
#907 530
International model with CAT Turbo (CE)
USA Model Full KVA Adapter Cord
#300 517
See page 6
USA Model Full KVA Plug Kit
#119 172
1-phase, 120/240 V, 50 A
International Plugs
#255 419 #255 416
1-phase, 120 V, 16 A 1-phase, 240 V, 16 A
Engine Filter Kits
#246 987 #252 782
For CAT. Includes air, oil and fuel filters For Mitsubishi. Includes air, oil and fuel filters
Spark Arrestor (Muffler) Kit
#300 585
See page 6
FA-1D Lockable Flame Arrestor Fuel Cap
#043 947
See page 6
Protective Cover
#195 301
See page 6
SuitCase® X-TREME™ 8VS
#951 583
With Bernard BTB Gun 300 A. See Lit. Index No. M/6.42
SuitCase® X-TREME™ 12VS
#951 544
With Bernard Dura-Flux gun. See Lit. Index No. M/6.42
SuitCase® 12RC
#951 188
With Bernard BTB Gun 300 A. See Lit. Index No. M/6.5
FieldPro™ Smart Feeder
#300 935
See Lit. Index No. PWS/6.0
Bernard™ PipeWorx 300 MIG Gun
#195 400
See Lit. Index No. PWS/6.0
Dynasty® 210
#907 685
Basic controls for AC/DC TIG/stick, 120 – 480 V. See Lit. Index No. AD/4.81
Dynasty® 210 DX
#907 686
Full feature controls for AC/DC TIG/stick, 120–480 V. See Lit. Index No. AD/4.81
HF-251D-1
#042 388
115 V. See Lit. Index No. AY/5.0
#907 529
Includes X-CASE™. See Lit. Index No. PC/9.2
®
®
Qty.
Field Accessories
MIG/Flux-Cored Welding
TIG Welding
Plasma Cutting Spectrum® 375 X-TREME™ Spectrum® 625 X-TREME™
#907 579
Includes X-CASE™. See Lit. Index No. PC/9.6
Spectrum® 875
#907 583
See Lit. Index No. PC/9.8
Remote Controls
See page 7
Trailers and Hitches HWY-224 Trailer
#043 805
Trailer with lights, fenders and 2-inch (50 mm) ball hitch. For highway use
Cable Tree
#043 826
Trailer-mounted cable holder for HWY-224
Dual Hitch
#300 831
Combination 2-inch (50 mm) ball hitch and 3-inch (76 mm) lunette eye in one reversible assembly for HWY-224
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