Miller Electric Big Blue 602P, Big Blue 402P, Big Blue 502P manual 11-1, 11-2, 11-3

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TABLE OF CONTENTS

SECTION 8

− OPERATING AUXILIARY EQUIPMENT

31

8-1.

120 Volt And 240 Volt Receptacles

31

8-2.

Connecting To Optional Three-Phase Generator (CC/CV Models Only)

32

8-3.

Optional Generator Power Receptacles

33

SECTION 9

− MAINTENANCE & TROUBLESHOOTING

34

9-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

9-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

9-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

9-6. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9-7. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

9-8. Diagnosing Causes Of Engine Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

9-9. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

SECTION 10 − ELECTRICAL DIAGRAMS

48

SECTION 11 − RUN-IN PROCEDURE

52

11-1.

Wetstacking

52

11-2.

Run-In Procedure Using Load Bank

53

11-3.

Run-In Procedure Using Resistance Grid

54

SECTION 12 − GENERATOR POWER GUIDELINES

55

SECTION 13 − PARTS LIST

62

OPTIONS AND ACCESSORIES

 

WARRANTY

 

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Contents Processes OM-491Description From Miller to You Table of Contents 11-2 11-111-3 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 électromagnétiquesSymbols And Definitions − Specifications− 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 PlaceInstalling Exhaust Pipe Using Lifting EyeStop engine and let cool Read and follow all instruc Activating The Dry Charge Battery If ApplicableCharger 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 StartRemote Amperage Control On CC Models Optional Connect optional remote control to RC13 see Section ExampleWeld Control/Arc Condition Information Label 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 ReceptaclesThree-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 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 Optional Three-Phase Generator Power CC/CV Models Only Standard Generator PowerEngine 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 Wetstacking − RUN-IN ProcedureWelding Generator 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-inSelecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame 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 Amperes114 113 110 109 116 − Parts List105 CC only 102 106 107 100 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 Your distributor also gives ServiceSupport 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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