Miller Electric Troubleshooting Common Welding Problems with the Miller Big Blue 300 and Pro 300
Page 48

8-12. Troubleshooting

. Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-11).

A. Welding

Trouble

Remedy

 

 

No weld output; generator power output

Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote

okay at ac receptacles.

On/Off Switch Required position and turn remote contactor on (see Section 5-9).

 

 

 

Reset supplementary protector CB7 or CB8 (see Section 8-9). Check for faulty remote device connected

 

to RC14.

 

 

 

Check and secure connections to Remote Control receptacle RC14 (see Section 5-9).

 

 

 

Check Voltmeter/Ammeter help displays (see Section 8-11).

 

 

No weld output, or generator power out-

Disconnect equipment from generator power receptacles during start-up.

put at ac receptacles.

 

 

 

 

Reset supplementary protector CB3. (see Section 8-9).

 

 

 

Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service

 

Agent check the voltage regulator module PC3.

 

 

 

Check Voltmeter/Ammeter help displays (see Section 8-11).

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings, voltage regulator module PC3, and

 

field excitation circuit.

 

 

Erratic weld output.

Check and tighten connections inside and outside unit.

 

 

 

Be sure connection to work piece is clean and tight.

 

 

 

Use dry, properly stored electrodes.

 

 

 

Remove excessive coils from weld cables.

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings.

 

 

High weld output.

Have Factory Authorized Service Agent check main control module PC1 and hall device HD1.

 

 

Low weld output.

Check engine speed, and adjust if necessary.

 

 

 

Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service

 

Agent check the rotor.

 

 

Low open-circuit voltage.

Check engine speed, and adjust if necessary.

 

 

 

Have Factory Authorized Service Agent check main control module PC1, voltage regulator module PC3,

 

and main rectifier.

 

 

No remote fine amperage control.

Repair or replace remote control device.

 

 

 

Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 5-9).

 

 

No 24 volt or 115 volt ac output at Re-

Reset supplementary protector CB7 (24 volt) or CB8 (115 volt) (see Section 8-9).

mote receptacle RC14.

 

 

 

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Contents OM-4433218 314P ProcessesDescription File Engine DriveFrom Miller to You Table of Contents Warranty Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiquesDES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu DES Organes Mobiles peuvent pro voquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicaux− Definitions − 50 h StdStd Manufacturer’s Rating Label Symbols And Definitions Some symbols are found only on CE products− Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Stick Mode MIG ModeTIG Mode Volt-Ampere CurvesCurve shows typical fuel use under weld or power loads Fuel ConsumptionDuty Cycle And Overheating This unit is rated for welding at 250 amperes continuouslyAC Generator Power Curve 150 125 100− Installation Installing Welding GeneratorLocation/Airflow Clearance Grounding1Mounting Welding Generator Supporting The UnitMounting Surface To Weld Unit In PlaceInstalling Exhaust Pipe Tools Needed 1/2Stop engine and let cool Point exhaust pipe in desired diActivating The Dry Charge Battery If Applicable Connecting The BatteryDo not overfill battery cells Close door after connecting batteryCoolant Recovery Tank Engine Prestart ChecksFuel OilConnecting To Weld Output Terminals Stick and TIG WeldingMIG and Fcaw Welding Stop engineStop engine Before Connecting to Weld Output terminals Selecting Weld Cable Sizes150 ft 200 ft 250 ft Connecting To Remote 14 Receptacle RC14 Socket InformationWelding Symbols − Operating Welding Generator Front Panel Controls See SectionDescription Of Front Panel Controls See Section Process/Contactor Switch Process/Contactor Switch SettingsLift-ArcStart Procedure Lift-Arc Start Method TouchDo not Strike Like a Match Lift-Arc t TIGRemote Voltage/Amperage Control Generator Power Receptacles − Operating Auxiliary EquipmentAt least once a month, run engine at − Maintenance & Troubleshooting Routine MaintenanceMaintenance Label Servicing Air Cleaner To clean air filterInspecting And Cleaning Optional Spark Arrestor Muffler Servicing Engine Cooling SystemAdjusting Engine Speed On Standard Models May affect engine warrantyMaximum Do not set engine speed higherEngine Speed Adjustment Weld/Power Speed AdjustmentEngine Speed No Load Rpm max 62.6 Hz 1500 rpm 50 HzServicing Fuel And Lubrication Systems To change oil and filterTo replace primary canister fuel filter To drain water from fuel systemOverload Protection Checking Generator Brushes Replace Damaged BrushesVoltmeter/Ammeter Help Displays Help 20 DisplayHelp 25 Display Troubleshooting WeldingGenerator Power EngineCheck for obstructed throttle solenoid Material Thickness Reference Chart − Electrical Diagrams Circuit Diagram For Welding Generator219 228−E − RUN-IN Procedure WetstackingWelding Generator Run-In Procedure Using Load Bank From flammablesOutput and do not exceed duty Cycle or equipment damage mayRun-In Procedure Using Resistance Grid − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated in electrical codes Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Parts List 101 111 110 −3 109 108 −2 107 102 103 9897 104 106 10580Fig.12−4 66654243 TE1 Dia Part Description Quantity Mkgs Batt Panel, Front w/Components Panel, Front w/Components -1ItemFUEL/HM Control Panel Generator Generator -1ItemRectifier Assembly Wiring Harnesses Service Your distributor also givesSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s

Big Blue 300 specifications

The Miller Electric Big Blue 300 is a powerful and versatile engine-driven welder that has become a popular choice for professionals in various industries. Designed to excel in both welding and generator applications, the Big Blue 300 provides reliable performance, advanced technology, and exceptional durability, making it suitable for demanding work environments.

One of the standout features of the Big Blue 300 is its impressive output capabilities. With a maximum welding output of 300 amps, this machine can handle a wide range of welding applications, from stick to TIG and MIG processes. The dual voltage output allows for versatility in the field, accommodating both 120V and 240V power requirements, ensuring you can power tools and equipment directly from the welder.

The Big Blue 300 is equipped with Miller's innovative Clean Air Technology, which ensures that the engine operates efficiently and produces fewer emissions. This feature not only meets environmental standards but also enhances the longevity of the machine. The cooling system is engineered to maintain optimal operating temperatures, extending the life of the engine and related components.

For ease of use, the Big Blue 300 features an intuitive control panel with easy-to-read gauges and simple adjustment settings, allowing operators to quickly set welding parameters. The built-in Fuel Gauge and Hour Meter provide real-time information about fuel levels and usage, enabling efficient operation and maintenance planning.

Another notable characteristic of the Big Blue 300 is its rugged construction. Built to withstand harsh job site conditions, the machine features a durable frame and heavy-duty components that can endure the rigors of everyday use. The oversized wheels and solid axle design enhance portability, making it easy to transport across various terrains.

Additionally, the Big Blue 300 is designed for quiet operation, making it suitable for locations where noise levels are a concern. Its low decibel rating ensures that it won’t disturb the work environment, contributing to a more comfortable and productive atmosphere.

Overall, the Miller Electric Big Blue 300 is a robust engine-driven welder that combines power, efficiency, and portability. Whether working on construction sites, maintenance tasks, or fabrication projects, this machine delivers exceptional performance and reliability, making it a valuable tool for professionals who demand the best in their equipment.
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