Miller Electric Big Blue 502P, Big Blue 402P, Big Blue 602P Troubleshooting, Welding − CC Models

Page 47

9-9. Troubleshooting

A. Welding − CC Models

Trouble

Remedy

 

 

No weld output; generator power output

Check position of Ampere Range switch.

okay at ac receptacles.

 

 

 

 

Check position of optional polarity switch.

 

 

 

Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote

 

control to Remote Amperage Adjust receptacle RC13 (see Sections 5-10and 6-1).

 

 

 

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-10).

 

 

 

Check fuse F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent check inte-

 

grated rectifier SR2 and the rotor.

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

 

 

No weld output or generator power out-

Disconnect equipment from generator power receptacles during start-up.

put at ac receptacles.

 

 

 

 

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent

 

check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.

 

 

 

Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (see Section 9-7).

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

 

 

Erratic weld output.

Check and tighten connections inside and outside unit.

 

 

 

Be sure connection to work piece is clean and tight.

 

 

 

Use dry, properly stored electrodes.

 

 

 

Remove excessive coils from weld cables.

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings.

 

 

High weld output.

Check engine speed, and adjust if necessary.

 

 

 

Have Factory Authorized Service Agent check OCV control circuit.

 

 

Low weld output.

Check engine speed, and adjust if necessary.

 

 

 

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent

 

check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.

 

 

Electrode sticks to the workpiece more

Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-7).

frequently during low voltage (short arc

Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.

length) conditions.

 

 

 

Low open-circuit voltage.

Check engine speed, and adjust if necessary.

 

 

Maximum weld output only in each

Have Factory Authorized Service Agent check control relay CR7.

ampere range (with Stick/TIG Selection

 

switch in Stick position).

 

 

 

No remote fine amperage control.

Place Amperage Adjust switch in correct position.

 

 

 

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-10).

 

 

 

Reset circuit breaker CB11 (see Section 9-7). Have Factory Authorized Service Agent check control relay

 

CR7.

 

 

 

Repair or replace remote control device.

 

 

 

Have Factory Authorized Service Agent check OCV control circuit.

 

 

Return To Table Of Contents

OM-491 Page 43

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Contents Description OM-491Processes From Miller to You Table of Contents 11-3 11-111-2 Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures graves’AIR Comprimé peut provoque r des blessures ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions − SpecificationsSymbols And Definitions Dimensions, Weights, And Operating Angles Weld, Power, And Engine Specifications55−90 Volt-Ampere Curves For CC ModelsVolt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG Mode100% Duty Cycle At 400 Amperes Exceeding duty cycle can damage unit and void warrantyFuel Consumption Duty Cycle And Overheating20 kVA/kW Three-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 12 kVA/kW Single-Phase AC Output No Weld LoadAirflow Clearance − InstallationInstalling Welding Generator Movement Location GroundingTo Bolt Unit In Place Mounting Welding GeneratorSupporting The Unit Mounting SurfaceStop engine and let cool Using Lifting EyeInstalling Exhaust Pipe Charger Activating The Dry Charge Battery If ApplicableRead and follow all instruc Connect Negative − Cable Last Connecting The BatteryOil Coolant Recovery TankEngine Prestart Checks Fuel Do not use gasoline. Gasoline will damage engineSelecting 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 ModelsTo Start Engine Indicator LightsDo not switch under load Engine Starting ControlsWeld Control/Arc Condition Information Label Connect optional remote control to RC13 see Section ExampleRemote Amperage Control On CC Models Optional 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 ModelsProcess Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control Stick Set Remote Set RangeVolt And 240 Volt Receptacles − Operating Auxiliary EquipmentRear 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 1000 h Every 400 hEvery 500 h Every 800 hMaintenance Label Do not clean housing with air hose Servicing Air CleanerBy the warranty To clean air filterReinstall cleanout plug Tools Needed 3/8 Inspecting And Cleaning Optional Spark Arrestor MufflerEngine Speed No Load Adjusting Engine SpeedModels With Automatic Idle Optional Idle Speed Adjustment Weld/Power Speed AdjustmentServicing Fuel And Lubrication Systems Stop engine Overload ProtectionCondition Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running Start Engine With No Load AppliedWelding − CC Models TroubleshootingWelding − CC/CV Models Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models Only Air in fuel system. See engine manual Shutdown switch is released OutTemperature is too high see Sections 5-7and Ing harness and componentsReturn To Table Of Contents Circuit Diagram For CC Welding Generator − Electrical Diagrams215 304-A Circuit Diagram For CC/CV Welding Generator 215 305-A Welding Generator − RUN-IN ProcedureWetstacking From flammables Do not Perform Run-In Procedure Using Load BankProcedure at less than Stop engine Do not touch hot exhaustDo not perform run-in Run-In Procedure Using Resistance GridBank/grid From flammablesGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsWork like a Pro Typical Connections To Supply Standby PowerCurrent Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible105 CC only 102 106 107 100 − Parts List114 113 110 109 116 115 114 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 Support ServiceYour distributor also gives Transportation Department Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s

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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