Miller Electric Big Blue 452P, Big Blue 302P manual From Miller to You

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Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance.

And if for some reason the unit needs repair, there’s a Troubleshooting section that will

help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Miller Electric manufactures a full line

of welders and welding related equipment. For information on other quality Miller

products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 7/03

Working as hard as you do

−every power source from Miller is backed by the most hassle-free warranty in the business.

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Contents Description OM-496Processes From Miller to You Table of Contents 11-3 11-111-2 Deccon1 11/02 DirectivesStandards Sound Level Information Deccon1 5/98Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures ’AIR Comprimé peut provoque r des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiques− Definitions + − Starting InstructionsCan cause severe burns. Do Are possible hazards asHot muffler and exhaust pipes EngineReturn To Table Of Contents Std Manufacturer’s Rating Labels For CE Products− 50 h Std CC Models CC/CV ModelsSymbols And Definitions Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Volt-Ampere Curves For CC Models TIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Duty Cycle And Overheating12 kVA/kW Single-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 15 kVA/kW Three-Phase AC Output No Weld LoadLocation Grounding − InstallationInstalling Welding Generator See Sections 5-2And Airflow ClearanceUsing Lifting Eye Work like a ProMounting Surface Mounting Welding GeneratorSupporting The Unit To Bolt Unit In PlaceInstalling Exhaust Pipe Stop engine and let coolRead and follow all instruc Activating The Dry Charge Battery If ApplicableWhen electrolyte is low, add ChargerConnect Negative − Cable Last Connecting The BatteryReinstall cover after connecting battery Coolant Recovery Tank Engine Prestart ChecksConnecting To Weld Output Terminals Selecting Weld Cable SizesRef 862-A / 048 720-K / 802 Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket− Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionDo not switch under load To Start Do not use ether. Using ether voids warrantyEngine Indicator Lights Engine Starting ControlsExample Combination Remote Amperage Control Stick Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label Set weld controls as shown toReturn To Table Of Contents − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionUse switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 ReceptacleProcess/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIGAt least once a month, run en − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles Open, contact Factory AuthoClose panel opening if no connections are made to generator Three-Phase Power ConnectionRear Of Panel Circuit Breaker CB2 Circuit Breaker CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 For Non-CE Products − Maintenance & TroubleshootingMaintenance Labels Every 50 h Routine MaintenanceEvery 8 h Every 100 hEvery 2000 h Clean/Set InjectorsEvery 1000 h Change FuelTo clean air filter Servicing Air CleanerBy the warranty Do not clean housing with air hoseInspecting And Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools NeededDo not set engine speed higher than specified Adjusting Engine Speed On Standard ModelsMaximum Close door Tools Needed 10 mmEngine Speed No Load Idle Speed AdjustmentWeld/Power Speed Adjustment Rpm max 61.6 Hz 1250 rpm 41.6 HzServicing Fuel And Lubrication Systems Overload Protection Correct the cause of the shut Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running Down before operatingTroubleshooting Welding − CC ModelsWelding − CC/CV Models Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models Only Temperature is too high see Sections 5-7and Wiring harness and componentsShutdown switch is released Out Air in fuel system. See engine manualReturn To Table Of Contents − Electrical Diagrams Circuit Diagram For CC Welding Generator215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-B Ment damage may occur − RUN-IN ProcedureWetstacking Stop engine Do not touch hot exhaust Run-In Procedure Using Load BankProcedure at less than From flammables Do not PerformFrom flammables Run-In Procedure Using Resistance GridBank/grid Do not perform run-inSelecting Equipment − Generator Power GuidelinesHas this symbol Grounding Generator To Truck Or Trailer FrameEarth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codesIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP xTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 109 111 -4 or118 85 FigDia Part Mkgs Description Quantity 209 Figures 13-2 Control Box Assembly − CC Models PLG3 Control Box Assembly − CC/CV Models PC7 195 Panel, Front w/Components − CC Models RC13 032 Panel, Front w/Components − CC/CV Models 41 40Panel, Front w/Components − CC/CV Models -1Item PC4, PC5 189 Generator Generator -1Item602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Page Page Support ServiceYour distributor also gives Your distributor and/or equipment manufacturer’s Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Transportation Department