Installation, Location Grounding | Miller Electric Big Blue 452P

SECTION 5 − INSTALLATION

5-1. Installing Welding Generator (See Sections 5-2And 5-3)

Movement

OR

OR

Location

OR

OR

Grounding

1

GND/PE2

Electrically bond generator frame to vehicle frame by metal-to-metal contact.

3Y Bed liners, shipping skids, and some running gears insulate the welding generator from the vehicle frame. Always connect a ground wire from the generator equipment grounding termi- nal to bare metal on the vehicle frame as shown.

Airflow Clearance

18 in

(460 mm)

18 in

18 in(460 mm)

(460 mm)

18 in

18 in(460 mm)

(460 mm)

YAlways securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.

YAlways ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards.

YIf unit does not have GFCI re- ceptacles, use GFCI-protected extension cord.

.See Section 5-3for mounting in- formation.

Grounding:

1Equipment Grounding Terminal (On Front Panel)

2Grounding Cable (Not Supplied)

3Metal Vehicle Frame

Connect cable from equipment ground terminal to metal vehicle frame. Use #10 AWG or larger insu- lated copper wire.

install3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274

OM-496 Page 20

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Miller Electric Big Blue 452P manual Installation, Installing Welding Generator See Sections 5-2And, Location Grounding

Contents

Description OM-496Processes From Miller to You Table of Contents 11-3 11-111-2 Deccon1 11/02 DirectivesStandards Sound Level Information Deccon1 5/98 Symbol Usage Arc Welding Hazards Engine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interference UN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereux DES 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’ouïe LA 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 blessures Principales normes de sécurité Information sur les champs électromagnétiques − Definitions + − Starting Instructions Can cause severe burns. Do Are possible hazards asHot muffler and exhaust pipes Engine Return To Table Of Contents Std Manufacturer’s Rating Labels For CE Products− 50 h Std CC Models CC/CV Models Symbols 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 Models Fuel Consumption Duty Cycle And Overheating 12 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 Load Location Grounding − InstallationInstalling Welding Generator See Sections 5-2And Airflow Clearance Using Lifting Eye Work like a Pro Mounting Surface Mounting Welding GeneratorSupporting The Unit To Bolt Unit In Place Installing Exhaust Pipe Stop engine and let cool Read and follow all instruc Activating The Dry Charge Battery If ApplicableWhen electrolyte is low, add Charger Connect Negative − Cable Last Connecting The BatteryReinstall cover after connecting battery Coolant Recovery Tank Engine Prestart Checks Connecting To Weld Output Terminals Selecting Weld Cable Sizes Ref 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 Section Do not switch under load To Start Do not use ether. Using ether voids warrantyEngine Indicator Lights Engine Starting Controls Example Combination Remote Amperage Control Stick Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label Set weld controls as shown to Return To Table Of Contents − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See Section Use switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 Receptacle Process/Contactor Switch On CC/CV Models Process/Contactor Switch Settings Remote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIG At least once a month, run en − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles Open, contact Factory Autho Close 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 h Every 2000 h Clean/Set InjectorsEvery 1000 h Change Fuel To clean air filter Servicing Air CleanerBy the warranty Do not clean housing with air hose Inspecting And Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools Needed Do not set engine speed higher than specified Adjusting Engine Speed On Standard ModelsMaximum Close door Tools Needed 10 mm Engine Speed No Load Idle Speed AdjustmentWeld/Power Speed Adjustment Rpm max 61.6 Hz 1250 rpm 41.6 Hz Servicing Fuel And Lubrication Systems Overload Protection Correct the cause of the shut Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running Down before operating Troubleshooting Welding − CC Models Welding − 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 manual Return To Table Of Contents − Electrical Diagrams Circuit Diagram For CC Welding Generator 215 296-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 Perform From flammables Run-In Procedure Using Resistance GridBank/grid Do not perform run-in Selecting Equipment − Generator Power GuidelinesHas this symbol Grounding Generator To Truck Or Trailer Frame Earth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codes Industrial 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 Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Single-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes − Parts List 109 111 -4 or 118 85 Fig Dia 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 40 Panel, Front w/Components − CC/CV Models -1Item PC4, PC5 189 Generator Generator -1Item 602 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