Miller Electric Big Blue 502P, Big Blue 402P, Big Blue 602P manual PC6 192

Page 77

Item

Dia.

 

Part

 

 

 

No.

 

Mkgs.

 

No.

Description

Quantity

 

 

 

 

 

Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)

 

 

 

 

 

 

 

 

. . .

5

. . . . . R1 .

. . .

. 193 118 . .

POT, cp flat 1t 2w 1k ohm linear

. . . 1

. . .

6

. . . . . S6 .

. . .

193 234 . .

SWITCH, rotary 6 position gold contacts (included in control box harness,

. . .

. . .

. .

. . . . . . . .

. . .

. . . . . . . . . . .

see 13-3)

. . . 1

. . .

7

. . . . . S5 .

. . .

. 011 609 . .

SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in

. . .

. . .

. .

. . . . . . . .

. . .

. . . . . . . . . . .

control box harness, see 13-3)

. . . 1

. . .

8

. .

. . . . . . . .

. . .

202 209 . .

SPACER, nylon

. . . 2

. . .

9

. . . . PC6

. . .

192 995 . .

CIRCUIT CARD ASSY, connector/receptacle

. . . 1

. . . 10

. .

. . CB5

. . .

139 266 . .

CIRCUIT BREAKER, man reset 1p 15a 250vac frict

. . . 1

. . . 11

. .

. . . S1 .

. . .

176 606 . .

SWITCH, ignition 4posn w/o handle

. . . 1

. . . 12

. .

. . . S2 .

. . .

021 467 . .

SWITCH, tgl spst 3a 250v off−none−(on) spd term

. . .1

. . . 13

. .

. . MS1

. . .

189 698 . .

SWITCH, magnetic manual reset low current

. . . 1

. . . 14

. .

. . CB1

. . .

201 083 . .

CIRCUIT BREAKER, man reset 2P 20 A, 250VAC

. . . 1

. . .

. . .

. .

. . . . . . . .

. . .

201 553 . .

CLIP, circuit breaker retaining

. . . 1

. . .

. . .

. .

. . . . . . . .

. . .

201 109 . .

HARNESS, generator power (consisting of)

. . . 1

. . . 15

. .

. . CB2

. . .

093 996 . . .

. CIRCUIT BREAKER, man reset 1P 20A 250VAC frict

. . . 1

. . . 16

. .

. GFCI1

. .

151 981 . . .

. RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI

. . . 1

. . . 17

. .

. . RC1 . . .

147 632 . . .

. RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R

. . . 1

. . . 18

. .

. . RC5 . . ♦182 954 . .

RCPT, str 3P4W 50A 125/250V

. . . 1

. . . 19

. .

. . . . . . . .

. . ♦025 248 . .

STAND-OFF, insul .250-20 x 1.2

. . . 1

. . . 20

. .

. . . . . . . .

. . ♦604 102 . .

CONNECTOR, clamp cable 1.000

. . . 1

. . . 21

. .

. . . . . . . .

. . ♦197 527 . .

GUARD, circuit breaker

. . . 1

. . . 22

. .

. . . . . . . .

. . ♦197 363 . .

TERMINAL, ring tng screw clamp

. . . 3

. . . 23

. .

. . CB7

. . ♦196 780 . .

CIRCUIT BREAKER, man reset 3p

. . . 1

. . . 24

. .

. . . . . . . .

. .

+201 106 . .

PANEL, generator power

. . . 1

. . . 24

. .

. . . . . . . .

. . ♦202 641 . .

PANEL, generator power ss

. . . 1

. . . 24

. .

. . . . . . . .

. +♦201 107 . .

PANEL, generator power (full kVA option)

. . . 1

. . . 25

. .

. . . . . . . .

. . ♦196 781 . .

BOOT, circuit breaker 3 pole

. . . 1

. . . 26

. .

. . . . . . . .

. . ♦197 508 . .

PLUG, protective

. . . 1

. . . 27

. .

. . . . . . . .

. . ♦077 440 . .

BUSHING, conduit 1 in

. . . 1

. . . 28

. .

. . . . . . . .

. . .

601 836 . .

NUT, 250−20 .50hex .19h brs

. . . 3

. . . 29

. .

. . . . . . . .

. . ♦197 291 . .

COVER, receptacle w/gasket

. . . 1

. . . 30

. .

. . . . . . . .

. . .

083 030 . .

STUD, brs .250−20 x 1.750 w/hex collar

. . . 1

. . .

. . .

. .

. . CT2

. . ♦197 433 . .

TRANSFORMER, current sensing

. . . 1

. . . 31

. .

. . . . . . . .

. . .

190 861 . .

LABEL, warning electric shock and moving parts

. . . 1

. . . 31

. .

. . . . . . . .

. . ♦197 399 . .

LABEL, warning 3 ph generator power

. . . 1

. . . 32

. .

. . . . . . . .

. . .

193 260 . .

COVER, receptacle 2.250 dia lexan

. . . 1

. . . 33

. .

. . . . . . . .

. . .

193 258 . .

COVER, receptacle GFCI

. . . 1

. . . 34

. .

. . . . . . . .

. . .

190 323 . .

BOOT, circuit breaker clear hex nut

. . . 1

. . . 35

. .

. . . S12

. . ♦195 825 . .

SWITCH, polarity

. . . 1

. . . 36

. .

. . . . . . . .

. . .

201 125 . .

PANEL, mtg terminal pwr output

. . . 1

. . . 36

. .

. . . . . . . .

. . .

199 303 . .

PANEL, mtg terminal pwr output ss

. . . 1

. . . 37

. .

PC4, PC5 .

189 744 . .

CIRCUIT CARD ASSEMBLY, filter hf

. . . 2

. . . 38

. .

. . . . . . . .

. . .

039 046 . .

TERMINAL, pwr output black

. . . 1

. . .

. . .

. .

. . . . . . . .

. . .

180 735 . .

WASHER, output stud

. . . 2

. . . 39

. .

. . . . . . . .

. . .

134 201 . .

STAND-OFF, support

. . . 12

. . . 40

. .

. . . . . . . .

. . .

181 169 . .

SPACER, output stud

. . . 2

. . . 41

. .

. . . . . . . .

. . .

186 621 . .

BOOT, generic output stud

. . . 2

. . . 42

. .

. . . . . . . .

. . ♦059 773 . .

HANDLE, switch

. . . 1

. . . 43

. .

. . . . . . . .

. . ♦010 647 . .

PIN, spring cs .156 x 1.250

. . . 1

. . . 44

. .

. . . . . . . .

. . .

039 047 . .

TERMINAL, pwr output red

. . . 1

. . . 45

. .

. . . . . . . .

. . ♦196 073 . .

LABEL, do not switch while welding

. . . 1

. . . 46

. .

. . . . . . . .

. . .

193 143 . .

BOOT, magnetic shutdown switch

. . . 1

. . . 47

. .

. . . . . . . .

. . .

021 385 . .

BOOT, toggle switch lever

. . . 1

. . . 48

. .

. . . . . . . .

. . .

. 119 014 . .

LEVER, switch black

. . . 1

. . . 49

. .

. . . . . . . .

. . .

190 323 . .

BOOT, circuit breaker clear hex nut

. . . 1

. . . 50

. .

. . . . . . . .

. . .

170 391 . .

CONN, circ ms protective cap size 20

. . . 1

. . . 51

. .

. . . PL1

. . .

191 241 . .

LED, red 12V 4 ind lights panel mtg round

. . . 1

Page 76 Page 78
Image 77
Page 76 Page 78
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 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 sécurité− Definitions − SpecificationsSymbols And 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 PlaceStop 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 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 StartWeld 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 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 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 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 Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models Only 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 Welding Generator − RUN-IN ProcedureWetstacking 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-inGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment 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 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 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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