Miller Electric Big Blue 602P, Big Blue 402P, Big Blue 502P manual OM-491, Processes, Description

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OM-491

190 355AP

October 2003

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

Big BlueR 402P, 502P, 602P

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Contents Processes OM-491Description From Miller to You Table of Contents 11-2 11-111-3 Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoque r des blessuresInformation sur les champs électromagnétiques Principales normes de sécuritéSymbols And Definitions − Specifications− Definitions Dimensions, Weights, And Operating Angles Weld, Power, And Engine Specifications55−90 Volt-Ampere Curves For CC ModelsMIG Mode Stick ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Exceeding duty cycle can damage unit and void warrantyDuty Cycle And Overheating 100% Duty Cycle At 400 AmperesOptional Three-Phase Generator Curves AC Generator Power Curve12 kVA/kW Single-Phase AC Output No Weld Load 20 kVA/kW Three-Phase AC Output No Weld LoadInstalling Welding Generator − InstallationMovement Location Grounding Airflow ClearanceSupporting The Unit Mounting Welding GeneratorMounting Surface To Bolt Unit In PlaceInstalling Exhaust Pipe Using Lifting EyeStop engine and let cool Read and follow all instruc Activating The Dry Charge Battery If ApplicableCharger Connect Negative − Cable Last Connecting The BatteryEngine Prestart Checks Coolant Recovery TankFuel Do not use gasoline. Gasoline will damage engine OilSelecting Weld Cable Sizes Connecting To Weld Output TerminalsSocket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsFront Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsDo not switch under load Engine Indicator LightsEngine Starting Controls To StartRemote Amperage Control On CC Models Optional Connect optional remote control to RC13 see Section ExampleWeld Control/Arc Condition Information Label OM-491 Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV ModelsVoltage/Amperage Adjust Switch And Remote 14 Receptacle Voltage/Amperage Adjust ControlProcess/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsExample Combination Remote Amperage Control Stick Remote Voltage/Amperage Control On CC/CV Models OptionalSet Remote Set Range ProcessVolt And 240 Volt Receptacles − Operating Auxiliary EquipmentThree-Phase Power Connection Single-Phase Power Connection Single-Phase Generator PowerRear Of Panel 240 V 15 a AC South African Receptacle RC1 Optional Generator Power ReceptaclesCircuit Breaker CB2 Circuit Breaker CB3 − Maintenance & Troubleshooting Every 500 h Every 400 hEvery 800 h Every 1000 hMaintenance Label By the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hoseReinstall cleanout plug Tools Needed 3/8 Inspecting And Cleaning Optional Spark Arrestor MufflerModels With Automatic Idle Optional Idle Speed Adjustment Adjusting Engine SpeedWeld/Power Speed Adjustment Engine Speed No LoadServicing Fuel And Lubrication Systems Stop engine Overload ProtectionDiagnostic Checks While Running Diagnosing Causes Of Engine Fault ShutdownsStart Engine With No Load Applied ConditionWelding − CC Models TroubleshootingWelding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Only Standard Generator PowerEngine Temperature is too high see Sections 5-7and Shutdown switch is released OutIng harness and components Air in fuel system. See engine manualReturn To Table Of Contents Circuit Diagram For CC Welding Generator − Electrical Diagrams215 304-A Circuit Diagram For CC/CV Welding Generator 215 305-A Wetstacking − RUN-IN ProcedureWelding Generator Procedure at less than Run-In Procedure Using Load BankStop engine Do not touch hot exhaust From flammables Do not PerformBank/grid Run-In Procedure Using Resistance GridFrom flammables Do not perform run-inSelecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP xWork like a Pro Typical Connections To Supply Standby PowerCurrent Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible114 113 110 109 116 − Parts List105 CC only 102 106 107 100 115 114 Big Blue 502, 602 OnlyDia Part Mkgs Description Quantity Dia Part 124 Control Box Assembly − CC Models Control Box Assembly − CC/CV Models Control Box Assembly − CC/CV Models -1Item Panel, Front w/Components − CC Models MS1 Panel, Front w/Components − CC/CV Models -1Item Panel, Front w/Components − CC/CV ModelsPC6 192 Generator Generator -1Item Main Rectifier Assembly Your distributor also gives ServiceSupport For assistance in filing or settling claims, contact Miller Electric Mfg. CoYour distributor and/or equipment manufacturer’s Transportation Department

Big Blue 602P, Big Blue 502P, Big Blue 402P specifications

Miller Electric is a well-respected name in the welding industry, known for its high-quality portable welders that cater to a wide range of applications. Among their iconic products are the Big Blue 502P, Big Blue 402P, and Big Blue 602P, each offering unique features and capabilities suited to professional welders.

The Miller Big Blue 502P is recognized for its robust construction and high-performance capabilities. Powered by a reliable diesel engine, it provides 500 amps of welding power at a duty cycle of 100%. This model is particularly favored for its versatility, accommodating both stick and TIG welding processes. One of its key technologies is the Auto-Set feature, which automatically adjusts settings for optimal performance based on the material thickness. This welder also boasts a user-friendly interface, complete with easy-to-read digital displays for monitoring essential parameters.

In contrast, the Big Blue 402P offers a slightly lower welding output while maintaining many of the advanced features seen in its larger counterpart. With a maximum output of 400 amps, it is perfectly suited for light to medium-duty applications. The 402P is particularly lightweight for a diesel welder, making it an ideal choice for contractors who need mobility without sacrificing power. It includes the X-Mode technology, which ensures reliable performance in challenging conditions and offers an intuitive control panel for ease of use.

The Big Blue 602P, on the other hand, stands out for its high output and exceptional reliability. With a maximum capacity of 600 amps, this machine is designed for heavy-duty applications, making it perfect for industrial settings. The welder features advanced cooling systems and robust construction, which enhance durability and longevity. One notable characteristic of the 602P is its ability to handle various welding processes, including Stick, TIG, and MIG, making it a versatile tool for skilled welders. Additionally, the Big Blue 602P incorporates advanced inverter technology, resulting in a lighter and more energy-efficient model without compromising power performance.

All three models benefit from Miller's commitment to innovation and user-centric design features. Built to thrive in tough work environments, the Big Blue series is equipped with protective casings and vibration-resistant components. Safety is also a priority, with several built-in features that help protect users during operation.

In summary, the Miller Electric Big Blue 502P, 402P, and 602P each bring unique strengths to the welding market. Their notable features include advanced technologies, robust construction, and versatile applications, ensuring that professionals have the right tool for any welding job. Whether for light-duty tasks or heavy industrial applications, Miller Electric's Big Blue series remains a cornerstone for welders around the globe.