Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Big Blue 602P manual Big BlueR 402P, 502P, 602P, OM-491, Processes, Description

Models: Big Blue 402P

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OM-491

190 355AP

October 2003

Processes

Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

Description

Engine Driven Welding Generator

Big BlueR 402P, 502P, 602P

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Miller Electric Big Blue 602P, Big Blue 402P manual Big BlueR 402P, 502P, 602P, OM-491, Processes, Description

Contents

OM-491 Big BlueR 402P, 502P, 602PProcesses DescriptionFrom Miller to You SECTION 5 − INSTALLATION TABLE OF CONTENTSOPTIONS AND ACCESSORIES TABLE OF CONTENTSWARRANTY SECTION1-2. Arc Welding Hazards 1-1. Symbol UsageSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Means “Note” not safety relatedBATTERY EXPLOSION can BLIND 1-3. Engine HazardsReturn To Table Of Contents WELDING can cause fire or explosion1-4. Compressed Air Hazards 1-5. Additional Symbols For Installation, Operation, And MaintenanceSTEAM AND HOT COOLANT can burn ENGINE EXHAUST GASES can kill1-6. California Proposition 65 Warnings 1-7. Principal Safety Standards1-8. EMF Information READ INSTRUCTIONSSECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 2-1. Signification des symboles2-2. Dangers relatifs au soudage à l’arc UN CHOC ÉLECTRIQUE peut tuerLE SOUDAGE peut provoquer un in- cendie ou une explosion 2-3. Dangers existant en relation avec le moteurDES PARTICULES VOLANTES peuvent blesser les yeux DES PIÈCES CHAUDES peuvent provoquer des brûlures gravesL’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE 2-4. Dangers liés à l’air compriméDES ORGANES MOBILES peuvent provoquer des blessures LA CHALEUR DU MOTEUR peut pro- voquer un incendie2-7. Information sur les champs électromagnétiques 2-6. Principales normes de sécuritéLE SURCHAUFFEMENT peut endom- mager le moteur électrique LES ÉTINCELLES VOLANTES ris- quent de provoquer des blessures3-1. Symbols And Definitions SECTION 4 − SPECIFICATIONSSECTION 3 − DEFINITIONS Return To Table Of Contents4-2. Dimensions, Weights, And Operating Angles 4-1. Weld, Power, And Engine Specifications300−Max 4-3. Volt-Ampere Curves For CC ModelsA. Stick Mode 4-4. Volt-Ampere Curves For CC/CV ModelsB. MIG Mode C. TIG Mode4-6. Duty Cycle And Overheating 4-5. Fuel Consumption1800 RPM IDLE 4-8. Optional Three-Phase Generator Curves 4-7. AC Generator Power CurveA. 12 kVA/kW Single-Phase AC Output No Weld Load B. 20 kVA/kW Three-Phase AC Output No Weld Load5-1. Installing Welding Generator SECTION 5 − INSTALLATIONReturn To Table Of Contents MovementUsing Mounting Brackets 5-2. Mounting Welding GeneratorSupporting The Unit Inadequate support5-4. Installing Exhaust Pipe 5-3. Using Lifting EyeReturn To Table Of Contents Y Stop engine and let coolWhen electrolyte is low, add 5-5. Activating The Dry Charge Battery If ApplicableReturn To Table Of Contents Y Read and follow all instrucReinstall cover after connecting battery 5-6. Connecting The BatteryReturn To Table Of Contents Y Connect Negative − Cable LastCheck radiator coolant level when fluid is low in recovery tank 5-7. Engine Prestart ChecksCoolant Recovery Tank Return To Table Of Contents5-9. Selecting Weld Cable Sizes 5-8. Connecting To Weld Output Terminals24 VOLTS AC 5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsREMOTE OUTPUTReturn To Table Of Contents 6-1. Front Panel Controls For CC Models See SectionSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS Engine Indicator Lights 6-2. Description Of Front Panel Controls For CC Models See SectionY Stop engine and fix trouble if Battery Charging light goes on Y Do not switch under load6-4. Weld Control/Arc Condition Information Label 6-3. Remote Amperage Control On CC Models OptionalReturn To Table Of Contents Set weld controls as shown toOM-491 Page Return To Table Of ContentsReturn To Table Of Contents 7-1. Front Panel Controls For CC/CV Models See SectionSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS Engine Indicator Lights 7-2. Description Of Front Panel Controls For CC/CV Models See SectionY Stop engine and fix trouble if Battery Charging light goes on Y Do not switch under loadProcess/Contactor Switch Settings 7-3. Process/Contactor Switch On CC/CV ModelsProcess/Contactor Switch switch is in an Electrode HotExample Combination Remote Amperage Control Stick 7-4. Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control TIG 8-1. 120 Volt And 240 Volt Receptacles SECTION 8 − OPERATING AUXILIARY EQUIPMENTrized Service Agent powerSingle-Phase Power Connection 8-2. Connecting To Optional Three-Phase Generator CC/CV Models OnlySingle-Phase Generator Power Three-Phase Power ConnectionGenerator power is not af- fected by weld output 8-3. Optional Generator Power ReceptaclesReturn To Table Of Contents European Receptacle9-1. Routine Maintenance SECTION 9 − MAINTENANCE & TROUBLESHOOTINGEvery 8 h Every 50 hEvery 500 h Every 400 hEvery 800 h Every 1000 hReturn To Table Of Contents Maintenance LabelOM-491 Page by the warranty 9-3. Servicing Air CleanerThe air cleaner primary element can To clean air filterY Stop engine and let cool 9-4. Inspecting And Cleaning Optional Spark Arrestor MufflerY Stop engine and let cool 802 160-E / Ref. 202Models With Automatic Idle Optional Idle Speed Adjustment 9-5. Adjusting Engine SpeedWeld/Power Speed Adjustment Return To Table Of ContentsY Stop engine and let cool 9-6. Servicing Fuel And Lubrication SystemsTo change oil and filter To drain water from fuel systemWhen a circuit breaker or fuse 9-7. Overload Protectionmore serious problem exists Service AgentPre-Start Diagnostic Checks 9-8. Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running Battery Charging, Fuel, And Temperature Lights OffReturn To Table Of Contents 9-9. TroubleshootingA. Welding − CC Models Trouble B. Welding − CC/CV ModelsRemedy D. Optional Three-Phase Generator Power CC/CV Models Only C. Standard Generator PowerReturn To Table Of Contents E. EngineEngine starts, but stops when Magnetic OM-491 Page Return To Table Of ContentsFigure 10-1. Circuit Diagram For CC Welding Generator SECTION 10 − ELECTRICAL DIAGRAMSReturn To Table Of Contents OM-491 Page Return To Table Of Contents215 304-A Return To Table Of Contents Figure 10-2. Circuit Diagram For CC/CV Welding GeneratorOM-491 Page OM-491 Page Return To Table Of Contents215 305-A 11-1. Wetstacking SECTION 11 − RUN-IN PROCEDUREprocedure at less than 11-2. Run-In Procedure Using Load BankReturn To Table Of Contents Y Stop engineprocedure at less than 11-3. Run-In Procedure Using Resistance GridStop engine Y Do not touch hot exhaust12-1. Selecting Equipment SECTION 12 − GENERATOR POWER GUIDELINES12-2. Grounding Generator To Truck Or Trailer Frame has this symbol12-4. How Much Power Does Equipment Require? 12-3. Grounding When Supplying Building Systemsearth ground if supplying Use ground device as stated in electrical codes12-6. Approximate Power Requirements For Farm/Home Equipment 12-5. Approximate Power Requirements For Industrial MotorsReturn To Table Of Contents Industrial MotorsContractor 12-7. Approximate Power Requirements For Contractor EquipmentRating Starting Watts12-9. How Much Power Can Generator Supply? 12-8. Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements Return To Table Of ContentsWork like a Pro 12-10. Typical Connections To Supply Standby PowerReturn To Table Of Contents 12-11. Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads CurrentFigure 13-1. Main Assembly SECTION 13 − PARTS LISTBig Blue 502, 602 Only Return To Table Of Contents46 FIG Figure 13-1. Main Assembly Figure 13-1. Main Assembly Continued CC CV Figure 13-1. Main Assembly ContinuedFigure13-2. Control Box Assembly − CC Models Figure 13-1 Item Figure 13-2. Control Box Assembly − CC Models802 551-E Figure 13-3. Control Box Assembly − CC/CV Models Figure 13-2. Control Box Assembly − CC Models Continued802 360-D Figure 13-3. Control Box Assembly − CC/CV Models Figure 13-1 Item Figure 13-4. Panel, Front w/Components − CC Models Figure 13-1 Item Figure 13-4. Panel, Front w/Components − CC Models802 266-D Optional Figure 13-4. Panel, Front w/Components − CC Models Continued802 332-F Figure 13-5. Panel, Front w/Components − CC/CV ModelsFigure 13-5. Panel, Front w/Components − CC/CV Models Continued Figure 13-6. Generator Figure 13-5. Panel, Front w/Components − CC/CV Models Continued802 267-B Figure 13-6. Generator Figure 13-1 Item Figure 13-7. Main Rectifier Assembly Figure 13-1 Item Figure 13-7. Main Rectifier AssemblyHardware is common and not available unless listedService Warranty Questions?Call 1-800-4-A-MILLER for your local Miller distributor SupportOwner’s Record For ServicePlease complete and retain with your personal records Always provide Model Name and Serial/Style Number