Miller Electric Big Blue 302P, Big Blue 452P manual Control Box Assembly − CC/CV Models

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Ref. 802 360

 

 

 

 

Figure 13-3. Control Box Assembly − CC/CV Models

 

Item

Dia.

Part

 

 

 

No.

 

Mkgs.

No.

 

Description

Quantity

 

 

 

 

Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1Item 106)

 

. . .

1

. . . F1, F2 . . *085 874 . .

FUSE, mintr cer slo-blo 10A 250V

. . . 2

. . .

2

.

. . . . . . . . . . . .

046 432 . .

HOLDER, fuse mintr .250 x 1.250

. . . 2

. . . 3

.

. . . . . . . . . . . .

201 077 . .

CONTROL BOX, lh . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 4

.

. . . . . . . . . . . .

201 078 . .

CONTROL BOX, rh . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

5

.

. . . . . . . . . . . .

201 079 . .

COVER, control box .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

6

.

. . . . . . . . . . . .

134 201 . .

STAND-OFF, support pc card

. . . 3

. . .

7

. . . . PC9 . . .

192 224 . .

CIRCUIT CARD ASSY, display

. . . 1

. . . 8 . . . . . C9

087 110 . .

CAPACITOR, elctlt 240uf 200VDC

. . . 1

. . .

9

.

. . . . . . . . . . . .

177 136 . .

CLAMP, capacitor 1.375dia

. . . 1

. . . .

. .

.

. . . . . . . . . . . . .

204 811 . .

HARNESS, control box, cv weld control (consisting of)

. . . 1

. . . 10

.

. . . SR1 . . .

035 704 . . .

. RECTIFIER, integ 40A 800V

. . . 1

. . . 11

.

. . . CR5 . . .

090 104 . . .

. RELAY, encl 12VDC SPST 30A/15VDC

. . . 1

. . . .

. .

.

. . . RC4 . . .

047 483 . . .

. CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . .

. . . 1

. . . .

. .

.

. . . RC3 . . .

158 466 . . .

. CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . .

. . . 1

. . . .

. . . . . . RC1 . . .

135 133 . . .

. CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg

. . . 1

. . . 12

 

CB11, 12, 13

139 266 . . .

. CIRCUIT BREAKER, man reset 1P 15A 250VAC frict

. . . 3

. . . .

. .

.

. . . . . . . . . . . .

148 850 . . .

. SOCKET, relay 5 pin

. . . 1

. . . .

. .

.

. . . . S6 . . . .

193 324 . . .

. SWITCH, rotary 6 position gold contacts

 

. . . .

. .

.

. . . . . . . . . . . . .

. . . . . . . . . . .

. (located on front panel, see 13-5)

. . . 1

. . . .

. .

.

. . . . S5

011 609 . . .

. SWITCH,tgl spdt 15a 125vac on−none−on spd term chr

 

. . . .

. .

.

. . . . . . . . . . . . .

. . . . . . . . . . .

. (located on front panel, see 13-5)

. . . 1

. . . .

. .

.

. . . . . . . . . . . .

150 316 . . .

. CONN, rect univ 039 6p/s 3row plug cable lkg

. . . 6

. . . .

. .

.

. . . . . . . . . . . .

177 859 . . .

. CONN, body 5 terminal (to engine control switch S1)

. . . 1

. . . .

. .

.

. . . . . . . . . . . .

193 183 . . .

. CONN, rect cinch 18 pin

. . . 1

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OM-496 Page 77

Page 82 Page 84
Image 83
Page 82 Page 84
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 Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures graves’AIR Comprimé peut provoque r des blessures ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions Starting Instructions + −Engine Are possible hazards asHot muffler and exhaust pipes Can cause severe burns. DoReturn To Table Of Contents CC Models CC/CV Models Manufacturer’s Rating Labels For CE Products− 50 h Std StdSymbols And Definitions Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Volt-Ampere Curves For CC Models Volt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG ModeDuty Cycle And Overheating Fuel Consumption15 kVA/kW Three-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 12 kVA/kW Single-Phase AC Output No Weld LoadAirflow Clearance − InstallationInstalling Welding Generator See Sections 5-2And Location GroundingWork like a Pro Using Lifting EyeTo Bolt Unit In Place Mounting Welding GeneratorSupporting The Unit Mounting SurfaceStop engine and let cool Installing Exhaust PipeCharger Activating The Dry Charge Battery If ApplicableWhen electrolyte is low, add Read and follow all instrucConnect 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 Starting Controls To Start Do not use ether. Using ether voids warrantyEngine Indicator Lights Do not switch under loadSet weld controls as shown to Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label Example Combination Remote Amperage Control StickReturn 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 OptionalOpen, contact Factory Autho − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles At least once a month, run enClose 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 100 h Routine MaintenanceEvery 8 h Every 50 hChange Fuel Clean/Set InjectorsEvery 1000 h Every 2000 hDo not clean housing with air hose Servicing Air CleanerBy the warranty To clean air filterReinstall cleanout plug Tools Needed Inspecting And Cleaning Optional Spark Arrestor MufflerClose door Tools Needed 10 mm Adjusting Engine Speed On Standard ModelsMaximum Do not set engine speed higher than specifiedRpm max 61.6 Hz 1250 rpm 41.6 Hz Idle Speed AdjustmentWeld/Power Speed Adjustment Engine Speed No LoadServicing Fuel And Lubrication Systems Overload Protection Down before operating Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running Correct the cause of the shutWelding − CC Models TroubleshootingWelding − CC/CV Models Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models Only Air in fuel system. See engine manual Wiring harness and componentsShutdown switch is released Out Temperature is too high see Sections 5-7andReturn 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 From flammables Do not Perform Run-In Procedure Using Load BankProcedure at less than Stop engine Do not touch hot exhaustDo not perform run-in Run-In Procedure Using Resistance GridBank/grid From flammablesGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesHas this symbol Selecting EquipmentUse ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical 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 Transportation Department Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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