Miller Electric Big Blue 302P, Big Blue 452P manual Use switch to select weld amperage range

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7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)

Engine Starting Controls

1 Magnetic Shutdown Switch

Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or engine temperature is too high.

2 Starting Aid Switch

Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing).

3 Engine Control Switch

Use switch to start engine, select engine speed ( if unit has auto idle option), and stop engine.

In Run position, engine runs at weld/power speed. In Run/Idle position (optional), engine runs at idle speed at no load and weld speed with load applied.

To Start:

YDo not use ether. Using ether voids warranty.

.If engine does not start, let engine come to a complete stop before attempting re- start.

Above 325 F (05 C): turn Engine Control switch to Start while pressing Shutdown switch. Release Engine Control switch when engine starts. Continue holding Shutdown switch until engine indicator lights go out.

Below 325 F (05 C): turn engine control switch to Run/Idle position. Push Starting Aid switch up for 60 seconds. While still holding Starting Aid switch, press Magnetic Shutdown switch and turn Engine Control switch to Start. Re- lease Engine Control switch and Starting Aid switch when engine starts. Continue holding Shutdown switch until engine indicator lights go out.

To Stop: turn Engine Control switch to Off position.

Engine Indicator Lights

4 Battery Charging Light

Light goes on if engine alternator is not charg- ing battery. Engine continues to run.

YStop engine and fix trouble if Battery Charging light goes on.

5 Engine Temperature Light

Light goes on and engine stops if engine tem- perature is above 221 ° F (105° C).

YStop engine and fix trouble if Engine Temperature light goes on.

6 Engine Oil Pressure Light

Light goes on and engine stops if oil pressure is below 5 psi (34 kPa). Light goes on momen- tarily during start-up but goes out when en- gine reaches normal oil pressure.

YStop engine and fix trouble if Engine Oil Pressure light stays on after start- up.

7 Fuel Light

Light is not active on this model.

8 Engine Hour Meter

Engine Gauges

.To read gauges and engine indicator lights with engine off, turn Engine Control switch to Run/Idle and press Magnetic Shutdown switch (see Section 9-9).

9 Fuel Gauge

Use gauge to check fuel level.

To check fuel level when engine is not run- ning, turn Engine Control switch to Run/Idle position and press Magnetic Shutdown switch.

10 Battery Voltmeter (Optional)

Use gauge to check battery voltage and moni- tor the engine charging system. The meter should read about 14 volts dc when the en- gine is running, and about 12 volts dc when the engine is stopped.

11Engine Coolant Temperature Gauge (Optional)

Normal temperature is 180 - 203° F (82 - 95° C). When equipped with gauge option, engine stops if temperature exceeds 220° F (104° C).

12 Engine Oil Pressure Gauge (Optional)

Normal pressure is 30 − 60 psi (207 − 414 kPa). When equipped with gauge option, en- gine stops if pressure is below 10 psi (69 kPa).

Weld Controls

13 Process/Contactor Switch

See Section 7-3for Process/Contactor switch information.

14 Ampere Range Switch

YDo not switch under load.

Use switch to select weld amperage range.

Use the lowest four ranges for Stick and TIG welding. Read the upper set of numbers at each range for Stick welding and the lower set at each range for TIG welding.

Use the highest range for MIG welding and for cutting and gouging (CAC-A).

For most welding applications, use lowest amperage range possible to help prevent arc outages.

15 Voltage/AmperageAdjust Control

With Process/Contactor switch in any Stick or TIG setting, use control to adjust amperage within range selected by Ampere Range switch. With Process/Contactor switch in any MIG position, use control to adjust voltage. With Voltage/Amperage Adjust Switch in Re- mote position, control limits the remote am- perage in TIG mode, but has no effect in Stick and MIG modes.

Weld output would be about 213 A DC with controls set as shown (50% of 110 to 315 A).

.The numbers around the control are for reference only and do not represent an actual percentage value.

16Voltage/Amperage Adjust Switch And Remote 14 Receptacle

Use switch to select front panel or remote voltage/amperage control. For remote con- trol, place switch in Remote position and con- nect remote control to Remote 14 receptacle RC14 (see Sections 5-11and 7-4).

17 Polarity Switch (Optional)

YDo not switch under load.

Use Polarity switch to change weld output. Select either DC Electrode Positive (DCEP) or DC Electrode Negative (DCEN).

18 Polarity/AC Switch (Optional)

YElectric shock can kill.

YDo not use AC output in damp areas, if movement is confined, or if there is a danger of falling.

YUse AC output ONLY if required for the welding process. If AC output is re- quired, use remote output control if present on unit.

YDo not switch under load.

Use Polarity/AC switch to select AC or DC weld output and DC weld output polarity. For Direct Current Electrode Negative (DCEN), turn switch to − (Negative) position. For Direct Current Electrode Positive (DCEP), turn switch to + (Positive) position. For weld pro- cesses that require alternating current (AC), use AC position.

Weld Meters

.Optional weld meters do not work with optional Polarity/AC switch in AC position.

19 DC Voltmeter (Optional)

Voltmeter displays voltage at the weld output terminals, but not necessarily the welding arc due to resistance of cable and connections.

20 DC Ammeter (Optional)

Ammeter displays amperage output of the unit.

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Contents Description OM-496Processes From Miller to You Table of Contents 11-3 11-111-2 Deccon1 11/02 DirectivesStandards Deccon1 5/98 Sound Level InformationArc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoque r des blessuresInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions Starting Instructions + −Hot muffler and exhaust pipes Are possible hazards asCan cause severe burns. Do EngineReturn To Table Of Contents − 50 h Std Manufacturer’s Rating Labels For CE ProductsStd CC Models CC/CV ModelsSymbols And Definitions Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Volt-Ampere Curves For CC Models MIG Mode Stick ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsDuty Cycle And Overheating Fuel ConsumptionOptional Three-Phase Generator Curves AC Generator Power Curve12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld LoadInstalling Welding Generator See Sections 5-2And − InstallationLocation Grounding Airflow ClearanceWork like a Pro Using Lifting EyeSupporting The Unit Mounting Welding GeneratorMounting Surface To Bolt Unit In PlaceStop engine and let cool Installing Exhaust PipeWhen electrolyte is low, add Activating The Dry Charge Battery If ApplicableRead and follow all instruc ChargerConnect Negative − Cable Last Connecting The BatteryReinstall cover after connecting battery Engine Prestart Checks Coolant Recovery TankSelecting Weld Cable Sizes Connecting To Weld Output TerminalsRef 862-A / 048 720-K / 802 Socket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsFront Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsEngine Indicator Lights To Start Do not use ether. Using ether voids warrantyDo not switch under load Engine Starting ControlsWeld Control/Arc Condition Information Label Remote Amperage Control On CC Models OptionalExample Combination Remote Amperage Control Stick Set weld controls as shown toReturn To Table Of Contents Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV ModelsVoltage/Amperage Adjust Switch And Remote 14 Receptacle Use switch to select weld amperage rangeProcess/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsExample Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models OptionalVolt And 240 Volt Receptacles − Operating Auxiliary EquipmentAt least once a month, run en 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 8 h Routine MaintenanceEvery 50 h Every 100 hEvery 1000 h Clean/Set InjectorsEvery 2000 h Change FuelBy the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hoseReinstall cleanout plug Tools Needed Inspecting And Cleaning Optional Spark Arrestor MufflerMaximum Adjusting Engine Speed On Standard ModelsDo not set engine speed higher than specified Close door Tools Needed 10 mmWeld/Power Speed Adjustment Idle Speed AdjustmentEngine Speed No Load Rpm max 61.6 Hz 1250 rpm 41.6 HzServicing Fuel And Lubrication Systems Overload Protection Diagnostic Checks While Running Diagnosing Causes Of Engine Fault ShutdownsCorrect the cause of the shut Down before operatingWelding − CC Models TroubleshootingWelding − CC/CV Models Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models Only Shutdown switch is released Out Wiring harness and componentsTemperature is too high see Sections 5-7and Air in fuel system. See engine manualReturn To Table Of Contents Circuit Diagram For CC Welding Generator − Electrical Diagrams215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-B Ment damage may occur − RUN-IN ProcedureWetstacking Procedure at less than Run-In Procedure Using Load BankStop engine Do not touch hot exhaust From flammables Do not PerformBank/grid Run-In Procedure Using Resistance GridFrom flammables Do not perform run-inHas this symbol − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer FrameHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Use ground device as stated in electrical codesApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP xTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible109 111 -4 or − Parts List85 Fig 118Dia 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 41 40 Panel, Front w/Components − CC/CV ModelsPanel, Front w/Components − CC/CV Models -1Item PC4, PC5 189 Generator -1Item Generator602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Page Page Support ServiceYour distributor also gives For assistance in filing or settling claims, contact Miller Electric Mfg. CoYour distributor and/or equipment manufacturer’s Transportation Department
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