Miller Electric Big Blue 452P Owner's Manual

Big Blue 302P And 452POM-496 197 761GJanuary 2001Visit our website atwww.MillerWelds.comProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and Gouging

OM-496 Page 4H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunic

OM-496 Page 5SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANTUTILISATIONrom _nd_fre 11/981-1. Signification des symbolesSignifie Mise en garde ! Soyez

OM-496 Page 6Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étince

OM-496 Page 7DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvemen

OM-496 Page 8LE RAYONNEMENT HAUTE FRÉ-QUENCE (H.F.) risque de provoquerdes interférences. Le rayonnement haute fréquence (H.F.) peutprovoquer des int

OM-496 Page 9SECTION 2 – DEFINITIONS2-1. Warning Label Definitions (CE Models Only)3/961 1.1 1.2 1.33 3.1 3.2 3.34 4.1S-176 105-A+2 2.1 2.2+5+7 7.1 7.

OM-496 Page 103/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Do not smoke and keepmatches and flames away frombattery.3

OM-496 Page 113/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Hot muffler and exhaust pipescan cause severe burns. Donot

OM-496 Page 121 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Fire hazard from leakingengine fuel. Fire can result fromweldin

OM-496 Page 133/961 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinstructions to install muffler.2 Read Owner’s Manual. Readl

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-496 Page 142-3. Symbols And DefinitionsSome symbols are found only on CE products.NOTEStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineStar

OM-496 Page 15SECTION 3 – SPECIFICATIONS3-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated WeldingOutputMaximumOpen-CircuitVo

OM-496 Page 163-3. Volt-Ampere Curves For CC Models198 864The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities o

OM-496 Page 173-4. Volt-Ampere Curves For CC/CV Models198 865 / 198 866 / 198 867The volt-ampere curves show theminimum and maximum voltageand amperag

OM-496 Page 183-5. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.199 0320.000.250.500.751.001.251.501.752.000 50 100 150 2

OM-496 Page 193-7. AC Auxiliary Power Curve193 018The ac power curve shows the aux-iliary power in amperes available atthe 120 and 240 volt receptacle

OM-496 Page 20SECTION 4 – INSTALLATION4-1. Installing Welding Generator (See Sections 4-2 And 4-3)install1 10/00 – Ref. ST-800 652 / Ref. ST-800 477-A

OM-496 Page 214-3. Mounting Welding GeneratorRef. 190 250-A / Ref. 802 169-ETools Needed:9/16 in1123Welding Unit In PlaceBolting Unit In Place Do not

OM-496 Page 224-5. Activating The Dry Charge Battery (If Applicable)Remove battery from unit.1 Eye Protection – SafetyGlasses Or Face Shield2 Rubber G

OM-496 Page 234-6. Connecting The Battery1/2 in–+ Connect Negative (–) Cable Last.Tools Needed:802 168-B / Ref. 197 784 / 802 313 / S-0756-CNotes

TABLE OF CONTENTSSECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1. . . .

OM-496 Page 244-7. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break-in

OM-496 Page 254-8. Connecting To Weld Output Terminals802 311-D Stop engine.1 Positive (+) Weld OutputTerminal2 Negative (–) Weld Output Ter-minalFor

OM-496 Page 264-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC ModelsRef. 154 862-A / 048 720-K / 802 311-D1 Remote Amperage AdjustRec

OM-496 Page 274-11. Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsSocket* Socket Information24 VOLTS ACA 24 volts ac. Protected by circuitbre

OM-496 Page 28SECTION 5 – OPERATING WELDING GENERATOR – CC MODELS5-1. Front Panel Controls For CC Models (See Section 5-2)17197 784 / 802 311-D15 1621

OM-496 Page 295-2. Description Of Front Panel Controls For CC Models (See Section 5-1)Engine Starting Controls1 Magnetic Shutdown SwitchUse switch dur

OM-496 Page 305-3. Remote Amperage Control On CC Models (Optional)1 Remote Amperage AdjustReceptacle RC13Connect optional remote control toRC13 (see S

OM-496 Page 31Notes

OM-496 Page 32SECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS6-1. Front Panel Controls For CC/CV Models (See Section 6-2)17197 785 / 802 311-D6

OM-496 Page 336-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1)Engine Starting Controls1 Magnetic Shutdown SwitchUse switch

TABLE OF CONTENTSSECTION 8 – MAINTENANCE & TROUBLESHOOTING 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Maintena

OM-496 Page 346-3. Process/Contactor Switch On CC/CV Models11 Process/Contactor Switch Weld output terminals are en-ergized when Process/Con-tactor s

OM-496 Page 356-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see Se

OM-496 Page 36SECTION 7 – OPERATING AUXILIARY EQUIPMENT7-1. 120 Volt And 240 Volt Duplex Receptacles191 624-A21 120 V 20 A AC GFCI Receptacle GFCI12 2

OM-496 Page 377-2. Connecting To Optional Auxiliary Power Plant (CC/CV Models Only)Ref. 197 399 / 802 332-E Place Process/Contactor switchin Electrod

OM-496 Page 387-3. Optional Auxiliary Power Receptacles21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 15 A AC EuropeanReceptacle RC13 240 V 15 A AC Aus

OM-496 Page 39SECTION 8 – MAINTENANCE & TROUBLESHOOTING8-1. Maintenance Labels For Non-CE Products For CE Products Only

OM-496 Page 408-2. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be used for anextended period.No

OM-496 Page 41500 hRepair OrReplaceDamagedCables.800 hClean/SetInjectors.*1000 hBlow Out OrVacuum Inside.During HeavyService,Clean Monthly.ORDrain Slu

OM-496 Page 428-3. Servicing Air Cleaner Stop engine. Do not run engine without aircleaner or with dirty element. En-gine damage caused by using ada

OM-496 Page 438-4. Inspecting And Cleaning Optional Spark Arrestor Muffler802 160-D / Ref. 197 784 Stop engine and let cool.1 Spark Arrestor Muffler2

dec_con1 5/98Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating lab

OM-496 Page 448-5. Adjusting Engine Speed On Standard Models802 490-D / 802 491 Stop engine and let cool.Engine speed is factory set andshould not re

OM-496 Page 458-6. Adjusting Engine Speed On Models With Automatic Idle (Optional)802 538-AAfter tuning engine, check engine speedwith tachometer or f

OM-496 Page 468-7. Servicing Fuel And Lubrication Systems802 490-D / Ref. 801 434 Stop engine and let cool. After servicing, start engineand check f

OM-496 Page 478-8. Overload Protection Stop engine. When a circuit breaker or fuseopens, it usually indicates amore serious problem exists.Contact F

OM-496 Page 488-9. Diagnosing Causes Of Engine Fault ShutdownsRef. 197 784Use the front panel engine lights tohelp determine the cause of an au-tomati

OM-496 Page 498-10. TroubleshootingA. Welding – CC ModelsTrouble RemedyNo weld output; auxiliary power outputokay.Check position of Ampere Range switc

OM-496 Page 50B. Welding – CC/CV ModelsTrouble RemedyNo weld output; auxiliary power outputokay.Place Process/Contactor switch in a Electrode Hot posi

OM-496 Page 51C. Standard Auxiliary PowerTrouble RemedyNo auxiliary power output; weld outputokay.Reset receptacle circuit breakers.No auxiliary power

OM-496 Page 52Trouble RemedyEngine starts, but stops when MagneticShutdown switch is released.When starting engine, continue holding Magnetic Shutdown

OM-496 Page 53Notes

OM-496 Page 54SECTION 9 – ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For CC Welding Generator

OM-496 Page 55201 219

OM-496 Page 56 Figure 9-2. Circuit Diagram For CC/CV Welding Generator

OM-496 Page 57201 218

OM-496 Page 58SECTION 10 – RUN-IN PROCEDURErun_in1 6/9610-1. Wetstacking1 Welding GeneratorRun diesel engines near rated out-put during run-in period

OM-496 Page 5910-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust

OM-496 Page 6010-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep ex

OM-496 Page 61SECTION 11 – AUXILIARY POWER GUIDELINES11-1. Selecting Equipmentaux_pwr 2/99 – Ref. ST-159 730 / ST-800 5771 Auxiliary Power Receptacles

OM-496 Page 6211-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulated

OM-496 Page 6311-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 30

OM-496 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGrom _nd_11/981-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith

OM-496 Page 6411-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-496 Page 6511-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-496 Page 6611-10. Typical Connections To Supply Standby PowerS-0405-A1 Power Company ServiceMeter2 Main and Branch OvercurrentProtection3 Double-Po

OM-496 Page 6711-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, us

OM-496 Page 68SECTION 12 – PARTS LIST Hardware is common andnot available unless listed.45671022232425273334104105106114111110 (CC Only)1151161171181

OM-496 Page 69802 550-C36373839404243454650100–(Fig. 12–4)996061626364656667697273101–(Fig. 12–2 or 12–3)102514452586891034153548889929091939474755576

OM-496 Page 70DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 189 824 PANEL, gen LH 1. . . . . . . . . . . . . . . . . . . .

OM-496 Page 71DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity42 191 176 PLUG, radiator access 1. . . . . . . . . . .

OM-496 Page 72DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity85 200 778 LABEL, diesel engine maintenance Perkins (CE

OM-496 Page 73802 551-A123456789101112131415Figure 12-2. Control Box Assembly – CC ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Control Box As

OM-496 Page 2Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flyin

OM-496 Page 74802 360123456789101112Figure 12-3. Control Box Assembly – CC/CV ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-3. Control Box Assembl

OM-496 Page 75 Hardware is common andnot available unless listed.802 266-D134567891215131821262728303336393840414243444510141120291237343519232253132

OM-496 Page 76DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-4. Panel, Front w/Components – CC Models (Continued)Quantity190 254 HARNESS, front panel wel

OM-496 Page 77DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-4. Panel, Front w/Components – CC Models (Continued)Quantity44 010 647 PIN, spring CS .156 x

OM-496 Page 78DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-5. Panel, Front w/Components – CC/CV Models (Figure 12-1 Item 119)Quantity1 197 785 PLATE SC

OM-496 Page 79DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-5. Panel, Front w/Components – CC/CV Models (Continued)Quantity31 ♦197 399 LABEL, warning 3

OM-496 Page 80 Hardware is common andnot available unless listed.802 552123456789101112131415161718192021222324162625272930313228343328Figure 12-6. G

OM-496 Page 81DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-6. Generator (Continued)Quantity23 198 631 NUT, m10 hex lock nut stl pld 4. . . . . . . .

OM-496 Page 82 Hardware is common andnot available unless listed.802 279-A123465789Figure 12-7. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs.Ite

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 7/00Your distributor also givesyou ...ServiceYou always get the fa

OM-496 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely in

PRINTED IN USA  2001 Miller Electric Mfg. Co. 1/01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US