Miller Electric Big Blue 300 P Owner's Manual
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Miller Electric Big Blue 300 P Owner's Manual

Engine driven welding generator
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Big Blue 300 P
OM-4433
218 314K
2006−11
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
File: Engine Drive

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Summary of Contents for Miller Electric Big Blue 300 P

  • Page 1 Visit our website at www.MillerWelds.com Big Blue 300 P OM-4433 218 314K 2006−11 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator File: Engine Drive...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 TABLE OF CONTENTS 8-5. Servicing Engine Cooling System 8-6. Adjusting Engine Speed On Standard Models 8-7. Adjusting Engine Speed On Models With Automatic Idle (Optional) 8-8. Servicing Fuel And Lubrication Systems 8-9. Overload Protection ..............8-10.

  • Page 5: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

  • Page 6: Engine Hazards

    WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.

  • Page 7: Compressed Air Hazards

    STEAM AND HOT COOLANT can burn. D If possible, check coolant level when engine is cold to avoid scalding. D Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). D If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.

  • Page 8: California Proposition 65 Warnings

    READ INSTRUCTIONS. D Use only genuine MILLER/Hobart replacement parts. D Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio naviga- tion, safety services, computers, and communica- tions equipment.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- cendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures.

  • Page 11: Dangers Liés À L'air Comprimé

    D Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. D Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. D Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- ver le bouchon.

  • Page 12: Proposition Californienne 65 Avertissements

    LIRE LES INSTRUCTIONS. D Utiliser seulement les pièces de rechange d’origine. D Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences.

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions 0 − 50 h Std. 50 h Std. Notes S-177 571 DIESEL 200A 0 − 200A API CD-MIL L 2104D, CD/SE, CD/SF Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler.

  • Page 14: Manufacturer's Rating Label

    3-2. Manufacturer’s Rating Label Ref. 218 304-A OM-4433 Page 10...

  • Page 15: Symbols And Definitions

    3-3. Symbols And Definitions NOTE Some symbols are found only on CE products. Stop Engine Starting Aid (Preheat) Check Injectors/ Pump Positive Amperes Engine Stick (SMAW) Welding Time Three Phase Electrode Connection Duty Cycle Rated Idle Speed Contactor On Fast (Run, Weld/ Power) Battery (Engine) Check Valve...

  • Page 16: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Welding Weld Output Rated Welding Mode Range Output 400 A, 23 Volts DC, 40% Duty Cycle 20 − 410 A 410 A 300 A, 32 Volts DC 300 A, 32 Volts DC CC/DC CC/DC 60% Duty Cycle...

  • Page 17: Volt-Ampere Curves

    4-3. Volt-Ampere Curves A. Stick Mode DC AMPERES B. MIG Mode DC AMPERES C. TIG Mode DC AMPERES The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown.

  • Page 18: Fuel Consumption

    4-4. Fuel Consumption 2.00 1.75 1.50 1.25 1.00 0.75 0.50 0.25 IDLE 0.00 DC WELD AMPERES AT 100% DUTY CYCLE 4-5. Duty Cycle And Overheating 1000 OM-4433 Page 14 100% Duty Cycle At 250 Amperes Continuous Welding 50 60 % DUTY CYCLE The curve shows typical fuel use under weld or power loads.

  • Page 19: Ac Generator Power Curve

    4-6. AC Generator Power Curve Notes AC AMPERES IN 240 V MODE AC AMPERES IN 120 V MODE MATERIAL THICKNESS REFERENCE CHART The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 217 519 24 Gauge (.025 in) 22 Gauge (.031 in)

  • Page 20: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Movement Location/Airflow Clearance 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) (460 mm) Grounding GND/PE OM-4433 Page 16 18 in (460 mm) 18 in Electrically bond generator frame to vehicle frame by metal-to-metal contact.

  • Page 21: Mounting Welding Generator

    5-2. Mounting Welding Generator Supporting The Unit Inadequate support. Y Do not use flexible mounts. Using Mounting Brackets Tools Needed: 9/16 in Welding Unit In Place Bolting Unit In Place Y Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion.

  • Page 22: Installing Exhaust Pipe

    5-3. Installing Exhaust Pipe Tools Needed: 1/2 in Notes OM-4433 Page 18 Y Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. 803 582 / Ref. 217 357-A Work like a Pro! Pros weld and cut safely.

  • Page 23: Activating The Dry Charge Battery (If Applicable)

    5-4. Activating The Dry Charge Battery (If Applicable) 5 A For 30 Minutes 30 A For 12 Minutes Tools Needed: 5-5. Connecting The Battery Tools Needed: 1/2 in − Y Always wear a face shield, rubber gloves and protective clothing when working on a battery.

  • Page 24: Engine Prestart Checks

    5-6. Engine Prestart Checks Full Diesel Full Check all engine fluids daily. Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.

  • Page 25: Connecting To Weld Output Terminals

    5-7. Connecting To Weld Output Terminals Y Stop engine. Work/Negative (−) Weld Output Terminal CV (wire) Weld Output Terminal CC (Stick/TIG) Weld Output Terminal Y Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal...

  • Page 26: Selecting Weld Cable Sizes

    5-8. Selecting Weld Cable Sizes* Weld Output Terminals Y Stop engine before Welding connecting to weld out- Amperes put terminals. Y Do not use worn, dam- aged, undersized, or poorly spliced cables. This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable. **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

  • Page 27: Connecting To Remote 14 Receptacle Rc14

    5-9. Connecting To Remote 14 Receptacle RC14 LDR-14 long distance remote (includes 120 V receptacle) *The remaining sockets are not used. Notes Socket* 24 volts ac. Protected by sup- plementary protector CB8. 24 VOLTS AC 24 VOLTS AC Contact closure to A completes 24 volt ac contactor control circuit.

  • Page 28: Section 6 − Operating Welding Generator

    SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls (See Section 6-2) 217 357-B / 803 563 OM-4433 Page 24...

  • Page 29: Description Of Front Panel Controls (See Section 6-1)

    6-2. Description Of Front Panel Controls (See Section 6-1) Engine Starting Controls Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). Engine Control Switch Use switch to start engine, select engine speed (if unit has auto idle option), and stop engine.

  • Page 30: Process/Contactor Switch

    6-3. Process/Contactor Switch Switch Setting Switch Setting Remote On/Off Switch Re- GTAW With HF Unit, Pulsing quired −TIG HF Required Or Device, Or Remote Control Scratch Start Remote On/Off Switch Stick (SMAW) With Remote On/Off Required − Stick Remote On/Off Switch MIG (GMAW) Required −...

  • Page 31: Lift-Arct Start Procedure

    6-4. Lift-Arc Start Procedure Lift-Arc Start Method “Touch” Do NOT Strike Like A Match! Notes 1 − 2 Seconds Lift-Arc t TIG With Lift-Arct TIG selected, start arc as follows: TIG Electrode Workpiece Turn gas on. Touch tungsten electrode to workpiece at weld start point.

  • Page 32: Remote Voltage/Amperage Control

    6-5. Remote Voltage/Amperage Control In Example: Min = 20 A DC Max = 205 A DC Connect Remote Control To Remote Receptacle RC14 Set TIG or STICK Process Connect Remote Control To Remote Receptacle RC14 Set WIRE Process OM-4433 Page 28 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-9).

  • Page 33: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles 120 V 20 A AC (shown) Receptacle RC5 and/or GFCI1 120 V 20 A AC GFCI (shown) Receptacle RC6 and/or GFCI2 240 V 50 A AC Receptacle RC11 RC5 / 6 and GFCI1 / 2 supply 60 Hz single- phase power at weld/power speed.

  • Page 34: Section 8 − Maintenance & Troubleshooting

    SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance n = Check Z = Change * To be done by Factory Authorized Service Agent Every Hours n Coolant Level n Fuel Level Every Hours ~ Air Cleaner Element ~ Weld Terminals Every Hours ~ Battery Terminals...

  • Page 35: Maintenance Label

    8-2. Maintenance Label OM-4433 Page 31...

  • Page 36: Servicing Air Cleaner

    8-3. Servicing Air Cleaner Keep nozzle 2 in (51 mm) from element. Blow OM-4433 Page 32 Optional Inspect aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 217 357-A Y Stop engine. Y Do not run engine without air cleaner or with dirty element.

  • Page 37: Inspecting And Cleaning Optional Spark Arrestor Muffler

    8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler Tools Needed: 3/8 in 8-5. Servicing Engine Cooling System Y Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole.

  • Page 38: Adjusting Engine Speed On Standard Models

    8-6. Adjusting Engine Speed On Standard Models Engine Speed RPM (Hz) (No Load) 1880 (61.7) Weld/Power Maximum OM-4433 Page 34 Y Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer or frequen- cy meter.

  • Page 39: Adjusting Engine Speed On Models With Automatic Idle (Optional)

    8-7. Adjusting Engine Speed On Models With Automatic Idle (Optional) Engine Speed (No Load) 1880 rpm max (62.6 Hz) 1250 rpm (41.6 Hz) To prevent solenoid damage, be sure a 1/8 in (3 mm) gap exists be- tween the engine low speed screw throttle lever when the...

  • Page 40: Servicing Fuel And Lubrication Systems

    8-8. Servicing Fuel And Lubrication Systems OM-4433 Page 36 Y Stop engine and let cool. Y After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary, and wipe up spilled fuel. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary (Canister) Fuel Filter Secondary (In-Line) Fuel...

  • Page 41: Overload Protection

    8-9. Overload Protection Y Stop engine. When a circuit breaker, supple- mentary protector, opens, it usually indicates a more serious problem exists. Contact Factory Service Agent. Fuse F1 F1 protects the stator exciter wind- ing from overload. If F1 opens, weld and generator power is low or stops entirely.

  • Page 42: Checking Generator Brushes

    8-10. Checking Generator Brushes Notes OM-4433 Page 38 5/16 in. (8 mm) Minimum Length 9/16 in. (14.3 mm) New Length Replace Damaged Brushes MATERIAL THICKNESS REFERENCE CHART Y Stop engine and let cool. Generator Brush With Spring Mark and disconnect leads at brush hold- er cap.

  • Page 43: Voltmeter/Ammeter Help Displays

    8-11. Voltmeter/Ammeter Help Displays HL.P HL.P HL.P HL.P HL.P HL.P Use the Voltmeter/Ammeter help displays to diagnose and correct fault conditions. Indicates a failure of meter display module PC2, or the wiring between PC2 and main control module PC1. If this display is shown, have Facto- ry Authorized Service Agent check PC1, PC2, and the wiring between PC1 and PC2.

  • Page 44: Troubleshooting

    8-12. Troubleshooting Note Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-11). A. Welding Trouble No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote okay at ac receptacles.
  • Page 45 B. Generator Power Trouble No generator power output at ac recep- Reset receptacle supplementary protector(s) (see Section 7-1). tacles; weld output okay. No generator power or weld output. Disconnect equipment from generator power receptacles during start-up. Check fuse F1, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check vol- tage regulator module PC3.
  • Page 46 Trouble Engine slowly stopped and cannot be Check fuel level. restarted. Check engine air and fuel filters (see Sections 8-3 and 8-8). See engine manual. Battery discharges between uses. Turn Engine Control switch off when unit is not running. Clean top of battery with baking soda and water solution; rinse with clear water. Recharge or replace battery if necessary.
  • Page 47 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in)

  • Page 48: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator OM-4433 Page 44...
  • Page 49 219 228−D OM-4433 Page 45...

  • Page 50: Section 10 − Run-In Procedure

    SECTION 10 − RUN-IN PROCEDURE 10-1. Wetstacking OM-4433 Page 46 run_in1 8/01 Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.

  • Page 51: Run-In Procedure Using Load Bank

    10-2. Run-In Procedure Using Load Bank Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 52: Run-In Procedure Using Resistance Grid

    10-3. Run-In Procedure Using Resistance Grid OM-4433 Page 48 Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 53: Section 11 − Generator Power Guidelines

    SECTION 11 − GENERATOR POWER GUIDELINES NOTE The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 11-1. Selecting Equipment 11-2. Grounding Generator To Truck Or Trailer Frame Electrically bond generator frame to vehicle frame by metal-to-metal contact.
  • Page 54 11-3. Grounding When Supplying Building Systems 11-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
  • Page 55 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 11-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 56 11-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
  • Page 57 11-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
  • Page 58 11-10. Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Utility Electrical Service Y Have only qualified persons perform these connections according to all applicable codes and safety practic- Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local...
  • Page 59 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 60: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 6 (Fig.12-5) 1 (Fig.12-3) 108 (Fig.12-2) OM-4433 Page 56 Figure 12-1. Main Assembly 25 26...
  • Page 61 81 (Fig. 12-4) 803 683-B OM-4433 Page 57...
  • Page 62 Item Dia. Part Mkgs....Figure 12−3 ....213504 ....213491 .
  • Page 63 Item Dia. Part Mkgs....220295 ....190190 .
  • Page 64 Item Dia. Part Mkgs....213266 ....212623 .
  • Page 65 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. Item Dia. Part Mkgs. Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 108) ....097926 .
  • Page 66 Item Dia. Part Mkgs. Figure 12-2. Panel, Front w/Components (Continued) ....214543 ....134201 .
  • Page 67 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. Item Dia. Part Mkgs. Figure 12-3. Control Panel (Figure 12-1 Item 1) ....220981 .
  • Page 68 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 17 16 Item Dia. Part Mkgs..ROTOR . . . 212474 ....053390 .
  • Page 69 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. Item Dia. Part Mkgs..... 217081 .
  • Page 70 Note Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness. Item Dia. Part Mkgs..... 231122 .
  • Page 71 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.
  • Page 72 File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2006 Miller Electric Mfg. Co. 2006−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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