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Welding System
Miller Electric
Big Blue 302P, Big Blue 452P
SECTION 7 OPERATING WELDING GENERATOR CC/CV MODELS
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SECTION
7 −
OPERA
TING WELDING GENERA
TOR − CC/CV MODELS
7-1.
Front Panel Controls For CC/CV Models (See Section 7-2 )
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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)
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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)
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5-3. Mounting W elding Generator
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5-5. Activating The Dry Charge Battery (If Applicable)
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5-7. Engine Prestart Checks
5-8. Connecting To Weld Output Terminals
5-9. Selecting Weld Cable Sizes*
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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
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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
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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
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SECTION 11 RUN-IN PROCEDURE
11-1. Wetstacking
11-2. Run-In Procedure Using Load Bank
11-3. Run-In Procedure Using Resistance Grid
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SECTION 12 GENERATOR POWER GUIDELINES
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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
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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