Miller Electric Big Blue 502P, Big Blue 402P, Big Blue 602P manual Voltage/Amperage Adjust Control

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7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)

Engine Starting Controls

1 Magnetic Shutdown Switch

Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or engine temperature is too high.

2 Starting Aid Switch

Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing).

3 Engine Control Switch

Use switch to start engine, select engine speed ( if unit has auto idle option), and stop engine.

In Run position, engine runs at weld/power speed. In Run/Idle position (optional), engine runs at idle speed at no load and weld speed with load applied.

To Start:

.If engine does not start, let engine come to a complete stop before attempting re- start.

Above 325 F (05 C): turn Engine Control switch to Start while pressing Shutdown switch. Release Engine Control switch when engine starts. Continue holding Shutdown switch until engine indicator lights go out.

Below 325 F (05 C): turn engine control switch to Run/Idle position. Push Starting Aid switch up for 60 seconds. While still holding Starting Aid switch, press Magnetic Shutdown switch and turn Engine Control switch to Start. Re- lease Engine Control switch and Starting Aid switch when engine starts. Continue holding Shutdown switch until engine indicator lights go out.

To Stop: turn Engine Control switch to Off position.

Engine Indicator Lights

4 Battery Charging Light

Light goes on if engine alternator is not charg- ing battery. Engine continues to run.

YStop engine and fix trouble if Battery Charging light goes on.

5 Engine Temperature Light

Light goes on and engine stops if engine tem- perature is above 221 ° F (105° C).

YStop engine and fix trouble if Engine Temperature light goes on.

6 Engine Oil Pressure Light

Light goes on and engine stops if oil pressure is below 10 psi (69 kPa). Light goes on mo- mentarily during start-up but goes out when engine reaches normal oil pressure.

YStop engine and fix trouble if Engine Oil Pressure light stays on after start- up.

7 Fuel Light

Light goes on and engine stops if fuel level is low. Add fuel to resume operation.

8Engine Hour Meter

Engine Gauges

.To read gauges and engine indicator lights with engine off, turn Engine Control switch to Run/Idle and press Magnetic Shutdown switch (see Section 9-8).

9 Fuel Gauge

Use gauge to check fuel level.

To check fuel level when engine is not run- ning, turn Engine Control switch to Run/Idle position and press Magnetic Shutdown switch.

10 Battery Voltmeter (Optional)

Use gauge to check battery voltage 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.

11Engine Coolant Temperature Gauge (Optional)

Normal temperature is 180 - 203° F (82 - 95° C). When equipped with gauge option, engine stops if temperature exceeds 220° F (104° C).

12 Engine Oil Pressure Gauge (Optional)

Normal pressure is 30 − 60 psi (207 − 414 kPa). When equipped with gauge option, en- gine stops if pressure is below 10 psi (69 kPa).

Weld Controls

13 Process/Contactor Switch

See Section 7-3for Process/Contactor switch information.

14 Ampere Range Switch

Use switch to select weld amperage range.

Use the lowest four ranges for Stick and TIG welding. Read the upper set of numbers at each range for Stick welding and the lower set at each range for TIG welding.

Use the highest range for MIG welding and for cutting and gouging (CAC-A).

For most welding applications, use lowest amperage range possible to help prevent arc outages.

YDo not switch under load.

15 Voltage/Amperage Adjust Control

With Process/Contactor switch in any Stick or TIG setting, use control to adjust amperage within range selected by Ampere Range switch. With Process/Contactor switch in any MIG position, use control to adjust voltage. With Voltage/Amperage Adjust Switch in Re- mote position, control limits the remote am- perage in TIG mode, but has no effect in Stick and MIG modes.

Weld output would be about 223 A DC with controls set as shown (50% of 125 to 320 A).

.The numbers around the control are for reference only and do not represent an actual percentage value.

16Voltage/Amperage Adjust Switch And Remote 14 Receptacle

Use switch to select front panel or remote voltage/amperage control. For remote con- trol, place switch in Remote position and con- nect remote control to Remote 14 receptacle RC14 (see Sections 5-11and 7-4).

17 Polarity Switch (Optional)

YDo not switch under load.

Use switch to change weld output. Select ei- ther DC Electrode Positive (DCEP) or DC Electrode Negative (DCEN).

Weld Meters

18 DC Voltmeter (Optional)

Voltmeter displays voltage at the weld output terminals, but not necessarily the welding arc due to resistance of cable and connections.

19 DC Ammeter (Optional)

Ammeter displays amperage output of the unit.

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Contents Description OM-491Processes From Miller to You Table of Contents 11-3 11-111-2 Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoque r des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiques− Definitions − SpecificationsSymbols And Definitions Weld, Power, And Engine Specifications Dimensions, Weights, And Operating AnglesVolt-Ampere Curves For CC Models 55−90Stick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsExceeding duty cycle can damage unit and void warranty Fuel ConsumptionDuty Cycle And Overheating 100% Duty Cycle At 400 AmperesAC Generator Power Curve Optional Three-Phase Generator Curves12 kVA/kW Single-Phase AC Output No Weld Load 20 kVA/kW Three-Phase AC Output No Weld Load− Installation Installing Welding GeneratorMovement Location Grounding Airflow ClearanceMounting Welding Generator Supporting The UnitMounting Surface To Bolt Unit In PlaceStop engine and let cool Using Lifting EyeInstalling Exhaust Pipe Charger Activating The Dry Charge Battery If ApplicableRead and follow all instruc Connecting The Battery Connect Negative − Cable LastCoolant Recovery Tank Engine Prestart ChecksFuel Do not use gasoline. Gasoline will damage engine OilConnecting To Weld Output Terminals Selecting Weld Cable SizesConnecting To Remote 14 Receptacle RC14 On CC/CV Models Socket− Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionEngine Indicator Lights Do not switch under loadEngine Starting Controls To StartWeld Control/Arc Condition Information Label Connect optional remote control to RC13 see Section ExampleRemote Amperage Control On CC Models Optional OM-491 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionVoltage/Amperage Adjust Control Voltage/Amperage Adjust Switch And Remote 14 ReceptacleProcess/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control StickSet Remote Set Range Process− Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesRear Of Panel Single-Phase Power Connection Single-Phase Generator PowerThree-Phase Power Connection Circuit Breaker CB2 Circuit Breaker CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 − Maintenance & Troubleshooting Every 400 h Every 500 hEvery 800 h Every 1000 hMaintenance Label Servicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hoseInspecting And Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools Needed 3/8Adjusting Engine Speed Models With Automatic Idle Optional Idle Speed AdjustmentWeld/Power Speed Adjustment Engine Speed No LoadServicing Fuel And Lubrication Systems Overload Protection Stop engineDiagnosing Causes Of Engine Fault Shutdowns Diagnostic Checks While RunningStart Engine With No Load Applied ConditionTroubleshooting Welding − CC ModelsWelding − CC/CV Models Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models Only Shutdown switch is released Out Temperature is too high see Sections 5-7andIng harness and components Air in fuel system. See engine manualReturn To Table Of Contents − Electrical Diagrams Circuit Diagram For CC Welding Generator215 304-A Circuit Diagram For CC/CV Welding Generator 215 305-A Welding Generator − RUN-IN ProcedureWetstacking Run-In Procedure Using Load Bank Procedure at less thanStop engine Do not touch hot exhaust From flammables Do not PerformRun-In Procedure Using Resistance Grid Bank/gridFrom flammables Do not perform run-inGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP xTypical Connections To Supply Standby Power Work like a ProSelecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes105 CC only 102 106 107 100 − Parts List114 113 110 109 116 Big Blue 502, 602 Only 115 114Dia 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 Panel, Front w/Components − CC/CV Models -1ItemPC6 192 Generator Generator -1Item Main Rectifier Assembly Support ServiceYour distributor also gives Miller Electric Mfg. Co For assistance in filing or settling claims, contactYour 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.
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