Miller Electric Big Blue 302P Owner'S Manual Download Page 1

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Big Blue 302P

Big Blue 452P

(CE Compliant)

OM-496

197 761AT

March 2004

Visit our website at

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

Summary of Contents for Big Blue 302P

Page 1: ...7 761AT March 2004 Visit our website at 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...

Page 2: ...ue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the...

Page 3: ...ves For CC CV Models 17 4 5 Fuel Consumption 18 4 6 Duty Cycle And Overheating 18 4 7 AC Generator Power Curve 19 4 8 Optional Three Phase Generator Curves 19 SECTION 5 INSTALLATION 20 5 1 Installing...

Page 4: ...ional Spark Arrestor Muffler 45 9 5 Adjusting Engine Speed On Standard Models 46 9 6 Adjusting Engine Speed On Models With Automatic Idle Optional 47 9 7 Servicing Fuel And Lubrication Systems 48 9 8...

Page 5: ...ility Directives 89 336 EEC 92 31 EEC Standards Safety Requirements for Arc Welding Equipment IEC 60974 1 1998 09 Rotating Electrical Machines Part 1 Rating and Performance IEC 34 1 1994 Rotating Elec...

Page 6: ...2000 14 EC Sound Level Information Measured Sound Power Level 98 dB Guaranteed Sound Power Level 98 dB This equipment conforms to requirements brought forth by 2000 14 EC Noise conformity assessment p...

Page 7: ...x or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conductor first double check connections Frequently inspect input power...

Page 8: ...hielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully CYLINDERS can expl...

Page 9: ...fill cap HOT METAL from air arc cutting and gouging can cause fire or explosion Do not cut or gouge near flammables Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury Do not...

Page 10: ...American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from Nation...

Page 11: ...c der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit Installer et mettre la terre correctement cet ap...

Page 12: ...pantalons sans revers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes Suivre les recommandat...

Page 13: ...dissement dans le vase d ex pansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur Si le moteur est chaud et que le liquide doit tre v rif...

Page 14: ...entaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail 2 6 Principales normes de s curit Safet...

Page 15: ...the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do...

Page 16: ...arity and make connections in numbered sequence shown 12 Once dead battery is charged disconnect cables in sequence shown 1 S 176 108 1 4 2 3 4 1 3 2 2 3 4 5 6 10 11 7 8 9 12 S 176 106 3 96 1 Warning...

Page 17: ...ols 2 Engine fuel plus flames or sparks can cause fire 3 Do not smoke while fueling or if near fuel 4 Stop engine before fueling 5 Do not fuel a hot engine 6 Use Diesel Fuel only S 176 104 3 96 1 Warn...

Page 18: ...signatedareas causing a possible fuel leak 3 Fuel tank is located inside base 4 Do not weld on base of unit 5 Weld only on supplied brackets or bolt unit down 1 5 3 4 2 1 Warning Watch Out There are p...

Page 19: ...e possible hazards as shown by the symbols Read Owner s Manual Follow instructions to activate battery 5 Check oil level Add oil if necessary 6 During the first 50 hours of operation keep welding load...

Page 20: ...V Volts Panel Local Remote Engine Air Temperature Or Engine Temperature Output Alternating Current Stick SMAW Welding Constant Current CC MIG GMAW Welding TIG GTAW Time h Hours s Seconds 1 Single Pha...

Page 21: ...tandard 4 kVA kW Generator Power Perkins 404 22 Water Cooled Four Cylinder 32 8 HP Diesel Engine 25 gal 95 L 4 2 Dimensions Weights And Operating Angles Dimensions Height 60 in 1524 mm to top of muffl...

Page 22: ...0 4 3 Volt Ampere Curves For CC Models 202 666 A The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall...

Page 23: ...urves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 DC AMPERES DC VOLTS Ranges Max 150 420 110 315 75 2...

Page 24: ...5 1 50 1 75 2 00 0 50 100 150 200 250 300 350 400 DC WELD AMPERES AT 100 DUTY CYCLE US GAL HR IDLE Continuous Welding 4 6 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit c...

Page 25: ...0 125 0 10 20 30 40 50 60 AC AMPERES IN 120V MODE 4 8 Optional Three Phase Generator Curves 198 868 198 869 The ac power curves show the gen erator power available in amperes at the single phase 120 2...

Page 26: ...ding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire Electr...

Page 27: ...il it snaps in place Lower lifting eye when not needed To lock the lifting eye in the upright position insert a 3 8 16 x 1 1 2 in carriage bolt through slot in bracket and secure with nut bolt and nut...

Page 28: ...Mounting Brackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 8 16 x 1 in Screws Sup...

Page 29: ...e 1 2 in Tools Needed Ref 802 311 Ref 201 841 Stop engine and let cool Point exhaust pipe in desired di rection but always away from front panel and direction of travel Notes Work like a Pro Pros weld...

Page 30: ...battery cells Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 6 Battery Charger Read and follow all instruc tions supplied wit...

Page 31: ...496 Page 25 Return To Table Of Contents 5 6 Connecting The Battery 1 2 in Connect Negative Cable Last Tools Needed 802 168 B Ref 201 841 802 313 S 0756 C Reinstall cover after connecting battery Note...

Page 32: ...add oil see maintenance label Coolant Check coolant level in radiator before start ing unit the first time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check c...

Page 33: ...le Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 100 ft 30 m or Less 150 ft 45 m 200 ft 60 m 250 ft 70 m 300 ft 90 m 350 ft 105 m 400 ft 120 m Weld Output Terminals...

Page 34: ...rage Adjust Receptacle RC13 On CC Models Ref 154 862 A 048 720 K 802 311 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 see Section 6 3 1 Notes Work like a Pro Pros w...

Page 35: ...emote control circuit common distance remote includes 120 V receptacle OUTPUT CONTROL E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust control at...

Page 36: ...6 Page 30 Return To Table Of Contents SECTION 6 OPERATING WELDING GENERATOR CC MODELS 6 1 Front Panel Controls For CC Models See Section 6 2 17 201 841 802 311 6 5 4 7 15 16 2 1 3 13 18 19 14 12 10 11...

Page 37: ...and moni tor the engine charging system The meter should read about 14 volts dc when the en gine is running and about 12 volts dc when the engine is stopped 11 Engine Coolant Temperature Gauge Optiona...

Page 38: ...Remote Amperage Control Stick Adjust Optional Remote Control Set Switches Set Range Set Control Ref 154 862 A Ref 181 711 A 802 311 In Example Range 100 to 205 A DC Percentage Of Range 50 Max About 1...

Page 39: ...OM 496 Page 33 Return To Table Of Contents Notes...

Page 40: ...34 Return To Table Of Contents SECTION 7 OPERATING WELDING GENERATOR CC CV MODELS 7 1 Front Panel Controls For CC CV Models See Section 7 2 201 579 802 311 D 6 5 4 7 2 1 3 14 19 20 15 12 10 11 9 8 16...

Page 41: ...he en gine is running and about 12 volts dc when the engine is stopped 11 Engine Coolant Temperature Gauge Optional Normal temperature is 180 203 F 82 95 C When equipped with gauge option engine stops...

Page 42: ...arc drive dig circuit provides addition al amperage during low voltage short arc length conditions to prevent stick ing electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG po...

Page 43: ...Adjust Switch Set Range Control Not Used In Remote Stick Mode Set Remote Process Example Combination Remote Amperage Control TIG Adjust Optional Remote Control Set V A Adjust Switch Set Range Set Con...

Page 44: ...d and press test button to verify GFCI is working properly 3 Circuit Breaker CB1 4 Circuit Breaker CB2 CB1 protects RC1 and the genera tor winding from overload If CB1 opens RC1 and GFCI1 do not work...

Page 45: ...2 Circuit Grounding Lead 7 Lead 90 Neutral 8 Isolated Neutral Terminal 9 Jumper Lead 42 10 Grounding Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neutral t...

Page 46: ...peed and press test button to verify GFCI is working properly 5 Circuit Breaker CB2 6 Circuit Breaker CB3 CB2 protects GFCI1 from overload If CB2 opens GFCI1 does not work Press button to reset breake...

Page 47: ...OM 496 Page 41 Return To Table Of Contents SECTION 9 MAINTENANCE TROUBLESHOOTING 9 1 Maintenance Labels For Non CE Products For CE Products Only...

Page 48: ...service and storage information Service unit more often if used in severe conditions To be done by Factory Authorized Service Agent Every 8 h Check Fluid Levels See Section 5 7 Wipe Up Spills Drain Wa...

Page 49: ...And Slip Rings Service More Often In Dirty Conditions Change Fuel Filters See Section 9 7 Check Valve Clearance Check Radiator Fluid Level See Section 5 7 Every 2000 h Clean Set Injectors Notes 16 Ga...

Page 50: ...e place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primar...

Page 51: ...e and let cool 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole If nothing bl...

Page 52: ...st speed as follows Start engine and run until warm On CC Models place Stick TIG switch in Stick position On CC CV models turn Process Contactor switch to Stick Elec trode Hot position 1 Lock Nut 2 Ad...

Page 53: ...le position Turn throttle rod and plunger until engine runs at idle speed Tighten locknut Be sure solenoid plunger pulls all the way in bottoms when energized If necessary move linkage to other hole i...

Page 54: ...r free fuel flows To replace primary fuel filter Turn filter counterclockwise Re move filter Fill new filter with fresh fuel Apply thin coat of fuel to gasket on new fil ter Install new filter and tur...

Page 55: ...ts the 24 volt ac output to remote receptacle RC14 and 24 volt output to field current regulator board PC1 CC CV models only If CB5 opens weld output and 24 volt output to RC14 stops On units with opt...

Page 56: ...thorized Service Agent If Battery Charging Light Is On Have Factory Authorized Service Agent Check Alternator If Temperature Light Is On Correct Cause Of Overheating See Engine Manual If Engine Is Oka...

Page 57: ...ons 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 b...

Page 58: ...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 Check position of Ampere...

Page 59: ...and replace if open see Section 9 8 Have Factory Authorized Service Agent check inte grated rectifier SR1 resistor R3 and capacitor C9 D Optional Three Phase Generator Power CC CV Models Only Trouble...

Page 60: ...tion Use correct grade oil for cold weather see Section 9 1 Engine suddenly stops Check oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant temperaturei...

Page 61: ...OM 496 Page 55 Return To Table Of Contents Notes...

Page 62: ...OM 496 Page 56 Return To Table Of Contents SECTION 10 ELECTRICAL DIAGRAMS Figure 10 1 Circuit Diagram For CC Welding Generator...

Page 63: ...OM 496 Page 57 Return To Table Of Contents 215 296 B...

Page 64: ...OM 496 Page 58 Return To Table Of Contents Figure 10 2 Circuit Diagram For CC CV Welding Generator...

Page 65: ...OM 496 Page 59 Return To Table Of Contents 215 297 B...

Page 66: ...ating label or specifications section in this manual to find rated voltage and current Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the weldin...

Page 67: ...ther DC position 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minu...

Page 68: ...ls using proper size weld cables with correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and...

Page 69: ...2 Grounding Generator To Truck Or Trailer Frame S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Equipment Grounding Terminal On Front...

Page 70: ...ower 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 12 8 3 Rating Data Rat...

Page 71: ...uipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Coole...

Page 72: ...3000 1000 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric C...

Page 73: ...nduction Motor Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor...

Page 74: ...mer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Connect generator with tem...

Page 75: ...5 38 75 23 50 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI recept...

Page 76: ...ommon and not available unless listed 17 18 19 15 16 26 25 24 22 23 1 2 3 4 5 6 7 10 11 12 13 14 20 21 103 102 101 100 104 99 98 107 CC ONLY 108 106 FIG 13 2 OR 13 3 105 12 109 110 111 FIG 13 4 OR 13...

Page 77: ...nts 802 550 E 85 Fig 13 6 84 43 56 57 41 55 33 36 37 72 73 76 74 75 77 78 58 59 38 60 40 54 79 80 82 86 32 27 28 29 30 31 34 35 87 88 89 90 91 92 93 94 95 96 97 71 69 68 67 66 65 64 63 62 61 44 53 70...

Page 78: ...safety 1 17 189 618 HOSE air cleaner 1 18 198 457 TUBE air intake perkins 104 22 1 19 173 036 HOSE elbow air cleaner 1 010 863 CLAMP hose 1 125 3 000 clp dia 4 20 189 464 SEAL weather lift eye 1 173 9...

Page 79: ...lind CE models only 1 53 201 996 LABEL warning do not operate with guard missing 2 54 197 496 HOSE radiator lower perkins 104 22 1 199 505 HOSE oil drain assy 32 in consisting of 1 55 165 271 VALVE oi...

Page 80: ...arbed elbow zinc pld 1 93 190 142 SENDER fuel gauge 9 7500 deep tank 1 94 189 910 FITTING stand pipe hose 3125 x 9 260 lg 90deg zinc 1 95 189 908 VALVE drain fuel 180deg 1 96 181 572 BUSHING tank fuel...

Page 81: ...d Order label individually or as part of Label Kit 202 021 or Label Kit 201 061 CE models only Recommended Spare Parts C C CC models only C V CC CV models only Optional To maintain the factory origina...

Page 82: ...AKER man reset 1P 15A 250VAC frict 3 190 260 HARNESS unit weld control consisting of 1 PLG3 158465 CONN rect univ 084 12p s 3row plug cable lkg 1 187654 SEAL wire univ 12p s 3row 1 PLG6 114063 CONN re...

Page 83: ...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...

Page 84: ...LAY encl 12VDC SPST 30A 15VDC spin flange mtg 3 212 452 HARNESS engine control consisting of 1 17 D10 C10 D11 C11 189 701 DIODE CAPACITOR BOARD 2 18 R8 217 335 RESISTOR BOARD 1 19 CB10 190 374 CIRCUIT...

Page 85: ...13 1 Item 111 Quantity 1 201 841 PLATE SCREENED ident control rating when ordering this item the nameplate should also be ordered 1 2 NAMEPLATE screened order by model and serial number 1 3 201 580 PA...

Page 86: ...s CE models only 1 18 201 106 PANEL gen pwr 1 18 202 641 PANEL gen pwr ss 1 18 201 052 PANEL gen pwr CE models only 1 18 210 750 PANEL gen pwr ss CE models only 1 19 083 030 STUD brs 250 20 x 1 750 w...

Page 87: ...abel should also be ordered Order label individually or as part of Label Kit 202 021 or Label Kit 201 061 CE models only To maintain the factory original performance of your equipment use only Manufac...

Page 88: ...981 RECEPTACLE str dx grd 2P3W 15 20A 125V GFCI 1 17 RC1 147 632 RECEPTACLE tw lk grd 2P3W 30A 250V L6 30R 1 201 053 HARNESS generator power CE models only consisting of 1 15 CB2 093 996 CIRCUIT BREAK...

Page 89: ...ngine only 1 56 193 227 GAUGE Pressure Oil 0 100 Psi Electric Switch 1 193 230 SENDER Pressure Oil 0 100 Psi 1 57 194 348 AMMETER W Leads 1 030 084 SHUNT Meter 50mv 600 Amp Lt Wt 1 58 194 345 VOLT MET...

Page 90: ...ete full kVA option 1 7 013 367 LABEL warning moving parts 2 7 176 106 LABEL warning moving parts CE models only 2 8 190 197 GUARD generator wire mesh 1 9 172 674 SPRING ext 240 OD x 041 wire x 3 500p...

Page 91: ...HER exciter 4 31 190 823 BRUSH contact 3 32 208 469 CLIP spring 3 33 189 142 BRUSHHOLDER ASSEMBLY gen 1 34 602 242 WASHER flat 375IDx0 875odx 083t stl pld 2 35 602 211 WASHER Lock 318idx0 586odx 078t...

Page 92: ...f 1 1 188 137 CONNECTION BOARD rectifier AC 1 2 188 517 BUS BAR connection board 3 3 188 135 ENCLOSURE rectifier 2 4 134 201 STAND OFF support 3 5 PC3 201 449 CIRCUIT CARD ASSEMBLY protection 1 6 188...

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Page 95: ...rols Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles con...

Page 96: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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