Miller Electric Big Blue 302P, Big Blue 452P manual

Big Blue 302P

Big Blue 452P (CE Compliant )

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OM-496 197 761AT

March 2004

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www.MillerWelds.com

Processes

Description

Air Carbon Arc (CAC-A)

Cutting and Gouging

Stick (SMAW ) Welding

Engine Driven Welding Generator

TIG (GTAW) Welding

MIG (GMAW ) Welding

Flux Cored (FCAW ) Welding

And Non-CE Models

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Contents

Main Big Blue 302P Big Blue 452P And Non-CE Models From Miller to You Page TABLE OF CONTENTS Declaration of Conformity for European Community (CE) Products Appleton, WI 54914 USA Declaration of Conformity for European Community (CE) Products Appleton, WI 54914 USA OM-496 Page 1 Return To Table Of Contents SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING Warning: Protect yourself and others from injury read and follow these precautions. 1-1. Symbol Usage Marks a special safety message. 1-2. Arc Welding Hazards 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. FUEL can cause fire or explosion. MOVING PARTS can cause injury. OM-496 Page 3 1-4. Compressed Air Hazards cause serious injury or death. COMPRESSED AIR can cause injury HOSES can cause injury. HOT METAL from air arc cutting and gouging can cause fire or explosion. 1-6. California Proposition 65 Warnings 1-7. Principal Safety Standards 1-8. EMF Information OM-496 Page 5 Revenez la table des matires SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions. 2-1. Signification des symboles Identifie un message de scurit particulier. 2-2. Dangers relatifs au soudage larc 2-3. Dangers existant en relation avec le moteur LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou mme la mort. LACIDE DE LA BATTERIE peut pro- voquer d e s brlures dans les YEUX et sur la PEAU. OM-496 Page 7 Revenez la table des matires LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. 2-4. Dangers lis lair comprim RESPIRER LAIR COMPRIM peut pro voquer des blessures graves ou cause la mort. LAIR COMPRIM peut provoque 2-6. Principales normes de scurit 2-7. Information sur les champs lectromagntiques SECTION 3 DEFINITIONS 3-1. Warning Label Definitions (CE Models Only) + Page Page + 2 3 4 1+ A Hz X n U SECTION 4 SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Output Range Rated W elding Welding Mode Weld Output 4-3. Volt-Ampere Curves For CC Models 4-4. Volt-Ampere Curves For CC/CV Models 4-5. Fuel Consumption 4-6. Duty Cycle And Overheating 4-7. AC Generator Power Curve 4-8. Optional Three-Phase Generator Curves SECTION 5 INSTALLATION 5-1. Installing Welding Generator (See Sections 5-2 And 5-3) Page 5-3. Mounting W elding Generator Page 5-5. Activating The Dry Charge Battery (If Applicable) + Page 5-7. Engine Prestart Checks 5-8. Connecting To Weld Output Terminals 5-9. Selecting Weld Cable Sizes* Page 5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models Over 80,000 trained since 1930! Start Your Professional Welding Career Now! SECTION 6 OPERATING WELDING GENERATOR CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2 ) 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) 6-3. Remote Amperage Control On CC Models (Optional) 6-4. Weld Control/Arc Condition Information Label Page SECTION 7 OPERATING WELDING GENERATOR CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2 ) 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 7-3. Process/Contactor Switch On CC/CV Models Process/Contactor Switch Settings 7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) SECTION 8 OPERATING AUXILIARY EQUIPMENT 8-1. 120 Volt And 240 Volt Receptacles 8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) 8-3. Optional Generator Power Receptacles Page 9-2. Routine Maintenance Every 8 h Every 50 h Every 100 h Every 250 h Every 1000 h Every 2000 h 9-3. Servicing Air Cleaner 9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler 9-5. Adjusting Engine Speed On Standard Models RPM (Hz) 9-6. Adjusting Engine Speed On Models With Automatic Idle (Optional) 9-7. Servicing Fuel And Lubrication Systems 9-8. Overload Protection 9-9. Diagnosing Causes Of Engine Fault Shutdowns 9-10. Troubleshooting A. Welding CC Models B. Welding CC/CV Models C. Standard Generator Power D. Optional Three-Phase Generator Power (CC/CV Models Only) E. Engine Page Page Page Page Page Page SECTION 11 RUN-IN PROCEDURE 11-1. Wetstacking 11-2. Run-In Procedure Using Load Bank 11-3. Run-In Procedure Using Resistance Grid + SECTION 12 GENERATOR POWER GUIDELINES 1 12-1. Selecting Equipment 2-2. Grounding Generator To Truck Or Trailer Frame 12-3. Grounding When Supplying Building Systems 12-4. How Much Power Does Equipment Require? 12-5. Approximate Power Requirements For Industrial Motors 12-6. Approximate Power Requirements For Farm/Home Equipment 12-7. Approximate Power Requirements For Contractor Equipment 12-8. Power Required To Start Motor 12-9. How Much Power Can Generator Supply? 12-10.Typical Connections To Supply Standby Power Pros weld and cut safely. Read the safety rules at the beginning of this manual. 12-11. Selecting Extension Cord (Use Shortest Cord Possible) SECTION 13 PARTS LIST Figure 13-1. Main Assembly Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Effective January 1, 2003 (Equipment with a serial number preface of LC or newer) Please complete and retain with your personal records. For Service Always provide Model Name and Serial/Style Number. Owners Record