Miller Electric Big Blue 602P, Big Blue 402P manual Control Box Assembly − CC/CV Models -1Item

Page 73

Item

Dia.

 

Part

 

 

No.

 

Mkgs.

 

No.

Description

Quantity

 

 

 

 

 

Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1Item 104)

 

 

 

 

 

 

 

. . .

1

. . . F1, F2

. . *085 874 . .

FUSE, mintr cer slo-blo 10A 250V

. . . 2

. . .

2

.

. . . . . . . . .

. . .

046 432 . .

HOLDER, fuse mintr .250 x 1.250

. . . 2

. . . 3

.

. . . . . . . . .

. . .

201 077 . .

CONTROL BOX, lh

. . . 1

. . . 4

.

. . . . . . . . .

. . .

201 078 . .

CONTROL BOX, rh

. . . 1

. . .

5

.

. . . . . . . . .

. . .

201 079 . .

COVER, control box

. . . 1

. . .

6

.

. . . . . . . . .

. . .

134 201 . .

STAND-OFF, support pc card

. . . 3

. . .

7

. . . . PC9 . . .

192 224 . .

CIRCUIT CARD ASSY, display

. . . 1

. . . 8 . . . . . C9 .

. . .

. 087 110 . .

CAPACITOR, elctlt 240uf 200VDC

. . . 1

. . .

9

.

. . . . . . . . .

. . .

177 136 . .

CLAMP, capacitor 1.375dia

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

201 495 . .

HARNESS, control box, cv weld control (consisting of)

. . . 1

. . . 10

.

. . . SR1 . . .

035 704 . . .

. RECTIFIER, integ 40A 800V

. . . 1

. . . 11

.

. . . CR5 . . .

090 104 . . .

. RELAY, encl 12VDC SPST 30A/15VDC

. . . 1

. . . .

. .

.

. . . RC4 . . .

047 483 . . .

. CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . .

. . . 1

. . . .

. .

.

. . . RC3 . . .

158 466 . . .

. CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . .

. . . 1

. . . .

. . . . . . RC1 . . .

135 133 . . .

. CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg

. . . 1

. . . 12

 

CB11, 12, 13

139 266 . . .

. CIRCUIT BREAKER, man reset 1P 15A 250VAC frict

. . . 3

. . . .

. .

.

. . . . . . . . .

. . .

148 850 . . .

. SOCKET, relay 5 pin

. . . 1

. . . .

. .

.

. . . . S6 .

. . .

193 324 . . .

. SWITCH, rotary 6 position gold contacts

 

. . . .

. .

.

. . . . . . . . .

. . .

. . . . . . . . . . . .

. (located on front panel, see 13-5)

. . . 1

. . . .

. .

.

. . . . S5 .

. . .

. 011 609 . . .

. SWITCH,tgl spdt 15a 125vac on−none−on spd term chr

 

. . . .

. .

.

. . . . . . . . .

. . .

. . . . . . . . . . . .

. (located on front panel, see 13-5)

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

150 316 . . .

. CONN, rect univ 039 6p/s 3row plug cable lkg

. . . 6

. . . .

. .

.

. . . . . . . . .

. . .

177 859 . . .

. CONN, body 5 terminal (to engine control switch S1)

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

193 183 . . .

. CONN, rect cinch 18 pin

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

196 602 . . .

. PLUG, cavity 18,30 position cinch connector

. . . 4

. . . .

. .

.

. . . . . . . . .

. . .

196 603 . . .

. SEAL, switch 6 position rotary .250 shaft

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

141 450 . . .

. CONN, rect metrmate 10skt 1row plug cable lkg

. . . 1

. . . 13

.

. . . PC7

. . ♦195 706 . .

MODULE, pull to idle, two output, 7 pin

. . . 1

. . . 14

.

. . . CR4

. . ♦113 247 . .

RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg

. . . 1

. . . 15

.

. . . CR6 . .

♦090104 . .

RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg

. . . 1

. . . 16

.

. CR2, CR3 .

090 104 . .

RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg

. . . 2

. . . .

. .

.

. . . . . . . . .

. . .

205 970 . .

HARNESS, engine control (consisting of)

. . . 1

. . . 17

.

. . . . R8 .

. . .

189 701 . . .

. RESISTOR BOARD

. . . 1

. . . 18

.

. . . CB10

. . .

190 374 . . .

. CIRCUIT BREAKER, auto reset 12VDC 40A

. . . 1

. . . 19

.

. . . CR1 . . .

214 876 . . .

. RELAY, Encl 6vdc Spst 35a/14vdc 5 Pin

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

148 850 . . .

. SOCKET, relay 5 pin

. . . 2

. . . .

. .

.

. . . PLG4

. . .

. 114 062 . . .

. CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

185 655 . . .

. SEAL, wire univ 15P/S 3 row

. . . 1

. . . 20

.

. . . CR8 . . .

155 309 . .

CONTACTOR, solenoid 12VDC cont 400A inrush

. . . 1

♦Optional

 

 

 

 

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Page 72 Page 74
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Page 72 Page 74
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.
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