Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Big Blue 502P, Big Blue 402P, Big Blue 602P Weld, Power, And Engine Specifications

Models: Big Blue 402P

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4-1. Weld, Power, And Engine Specifications

4-1. Weld, Power, And Engine Specifications

				Maximum
	Welding	Weld Output	Rated Welding	Open-	Generator Power	Engine	Fuel
	Mode	Range	Output	Circuit	Rating	Engine	Capacity
	Mode	Range	Output	Circuit	Rating		Capacity
				Voltage

		55 − 600 A			Standard
		55 − 600 A		95	Single-Phase,
		(CC Models)			Single-Phase,
	CC/DC	(CC Models)			4 kVA/kW, 34/17 A,
			400 A, 40 Volts DC,		4 kVA/kW, 34/17 A,
		20 − 600 A			120/240 V AC,	Perkins
		20 − 600 A			120/240 V AC,	Perkins
		(CC/CV Models)	100% Duty Cycle		50/60 Hz
			500 A, 40 volts DC,		Three-Phase Generator	Perkins 3.1524	25 gal
			60% Duty Cycle		Option*	Water-Cooled,	(95 L)
	CV/DC		600 A, 30 Volts DC,		Single-Phase/Three-Phase,	Three-Cylinder,
	(CC/CV	14 − 40 V	40% Duty Cycle	56	12/20 kVA/kW, 50/48A,	45 HP Diesel Engine
	Models	14 − 40 V		56	120/240 VAC, 60 Hz
					120/240 VAC, 60 Hz
					*In Addition To Standard
	Only)				*In Addition To Standard
					4 kVA/kW Generator Power

4-2. Dimensions, Weights, And Operating Angles

Dimensions

	Height	50 in (1270 mm)
	Height	(to top of muffler)
		(to top of muffler)

		28-1/2 in (724 mm)
	Width	(mtg. brackets turned in)
	Width	30-3/4 in (781 mm)
		30-3/4 in (781 mm)
		(mtg. brackets turned out)

	Depth	65-1/8 in	(1654 mm)

	A	65-1/8 in	(1654 mm)

	B*	56 in (1422 mm)

	C*	46-1/2 in (1181)

	D*	9-5/8 in	(244 mm)

E27-1/2 in (699 mm)

F1 in (25 mm)

G29-1/2 in (743 mm)

9/16 in (14 mm) Dia.

H4 Holes

*With mounting brackets in center position. Dimensions vary with location of mounting brackets.

	Weight
w/ Perkins	No fuel: 1670 lb (758 kg)
3.1524	w/fuel: 1860 lb (844 kg)

A

B C

D

G

H

Front Panel End

F

E

802 161-A

G

YDo not exceed tilt angles or engine could be damaged or unit could tip.

YDo not move or operate unit where it could tip.

	30°
20°	30°
20°
20°

OM-491 Page 10

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Miller Electric Big Blue 502P manual Weld, Power, And Engine Specifications, Dimensions, Weights, And Operating Angles

Contents

Processes Big BlueR 402P, 502P, 602POM-491 DescriptionFrom Miller to You TABLE OF CONTENTS SECTION 5 − INSTALLATIONWARRANTY TABLE OF CONTENTSOPTIONS AND ACCESSORIES SECTIONSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage1-2. Arc Welding Hazards Means “Note” not safety relatedReturn To Table Of Contents 1-3. Engine HazardsBATTERY EXPLOSION can BLIND WELDING can cause fire or explosionSTEAM AND HOT COOLANT can burn 1-5. Additional Symbols For Installation, Operation, And Maintenance1-4. Compressed Air Hazards ENGINE EXHAUST GASES can kill1-8. EMF Information 1-7. Principal Safety Standards1-6. California Proposition 65 Warnings READ INSTRUCTIONS2-2. Dangers relatifs au soudage à l’arc 2-1. Signification des symbolesSECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION UN CHOC ÉLECTRIQUE peut tuerDES PARTICULES VOLANTES peuvent blesser les yeux 2-3. Dangers existant en relation avec le moteurLE SOUDAGE peut provoquer un in- cendie ou une explosion DES PIÈCES CHAUDES peuvent provoquer des brûlures gravesDES ORGANES MOBILES peuvent provoquer des blessures 2-4. Dangers liés à l’air compriméL’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE LA CHALEUR DU MOTEUR peut pro- voquer un incendieLE SURCHAUFFEMENT peut endom- mager le moteur électrique 2-6. Principales normes de sécurité2-7. Information sur les champs électromagnétiques LES ÉTINCELLES VOLANTES ris- quent de provoquer des blessuresSECTION 3 − DEFINITIONS SECTION 4 − SPECIFICATIONS3-1. Symbols And Definitions Return To Table Of Contents4-1. Weld, Power, And Engine Specifications 4-2. Dimensions, Weights, And Operating Angles4-3. Volt-Ampere Curves For CC Models 300−MaxB. MIG Mode 4-4. Volt-Ampere Curves For CC/CV ModelsA. Stick Mode C. TIG Mode1800 RPM IDLE 4-5. Fuel Consumption4-6. Duty Cycle And Overheating A. 12 kVA/kW Single-Phase AC Output No Weld Load 4-7. AC Generator Power Curve4-8. Optional Three-Phase Generator Curves B. 20 kVA/kW Three-Phase AC Output No Weld LoadReturn To Table Of Contents SECTION 5 − INSTALLATION5-1. Installing Welding Generator MovementSupporting The Unit 5-2. Mounting Welding GeneratorUsing Mounting Brackets Inadequate supportReturn To Table Of Contents 5-3. Using Lifting Eye5-4. Installing Exhaust Pipe Y Stop engine and let coolReturn To Table Of Contents 5-5. Activating The Dry Charge Battery If ApplicableWhen electrolyte is low, add Y Read and follow all instrucReturn To Table Of Contents 5-6. Connecting The BatteryReinstall cover after connecting battery Y Connect Negative − Cable LastCoolant Recovery Tank 5-7. Engine Prestart ChecksCheck radiator coolant level when fluid is low in recovery tank Return To Table Of Contents5-8. Connecting To Weld Output Terminals 5-9. Selecting Weld Cable SizesREMOTE 5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models24 VOLTS AC OUTPUTSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 6-1. Front Panel Controls For CC Models See SectionReturn To Table Of Contents Y Stop engine and fix trouble if Battery Charging light goes on 6-2. Description Of Front Panel Controls For CC Models See SectionEngine Indicator Lights Y Do not switch under loadReturn To Table Of Contents 6-3. Remote Amperage Control On CC Models Optional6-4. Weld Control/Arc Condition Information Label Set weld controls as shown toReturn To Table Of Contents OM-491 PageSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models See SectionReturn To Table Of Contents Y Stop engine and fix trouble if Battery Charging light goes on 7-2. Description Of Front Panel Controls For CC/CV Models See SectionEngine Indicator Lights Y Do not switch under loadProcess/Contactor Switch 7-3. Process/Contactor Switch On CC/CV ModelsProcess/Contactor Switch Settings switch is in an Electrode HotExample Combination Remote Amperage Control TIG 7-4. Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control Stick rized Service Agent SECTION 8 − OPERATING AUXILIARY EQUIPMENT8-1. 120 Volt And 240 Volt Receptacles powerSingle-Phase Generator Power 8-2. Connecting To Optional Three-Phase Generator CC/CV Models OnlySingle-Phase Power Connection Three-Phase Power ConnectionReturn To Table Of Contents 8-3. Optional Generator Power ReceptaclesGenerator power is not af- fected by weld output European ReceptacleEvery 8 h SECTION 9 − MAINTENANCE & TROUBLESHOOTING9-1. Routine Maintenance Every 50 hEvery 800 h Every 400 hEvery 500 h Every 1000 hOM-491 Page Maintenance LabelReturn To Table Of Contents The air cleaner primary element can 9-3. Servicing Air Cleanerby the warranty 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. 202Weld/Power Speed Adjustment 9-5. Adjusting Engine SpeedModels With Automatic Idle Optional Idle Speed Adjustment Return To Table Of ContentsTo change oil and filter 9-6. Servicing Fuel And Lubrication SystemsY Stop engine and let cool To drain water from fuel systemmore serious problem exists 9-7. Overload ProtectionWhen a circuit breaker or fuse Service AgentDiagnostic Checks While Running 9-8. Diagnosing Causes Of Engine Fault ShutdownsPre-Start Diagnostic Checks Battery Charging, Fuel, And Temperature Lights OffA. Welding − CC Models 9-9. TroubleshootingReturn To Table Of Contents Remedy B. Welding − CC/CV ModelsTrouble Return To Table Of Contents C. Standard Generator PowerD. Optional Three-Phase Generator Power CC/CV Models Only E. EngineEngine starts, but stops when Magnetic Return To Table Of Contents OM-491 PageReturn To Table Of Contents SECTION 10 − ELECTRICAL DIAGRAMSFigure 10-1. Circuit Diagram For CC Welding Generator 215 304-A Return To Table Of ContentsOM-491 Page OM-491 Page Figure 10-2. Circuit Diagram For CC/CV Welding GeneratorReturn To Table Of Contents 215 305-A Return To Table Of ContentsOM-491 Page SECTION 11 − RUN-IN PROCEDURE 11-1. WetstackingReturn To Table Of Contents 11-2. Run-In Procedure Using Load Bankprocedure at less than Y Stop engineStop engine 11-3. Run-In Procedure Using Resistance Gridprocedure at less than Y Do not touch hot exhaust12-2. Grounding Generator To Truck Or Trailer Frame SECTION 12 − GENERATOR POWER GUIDELINES12-1. Selecting Equipment has this symbolearth ground if supplying 12-3. Grounding When Supplying Building Systems12-4. How Much Power Does Equipment Require? Use ground device as stated in electrical codesReturn To Table Of Contents 12-5. Approximate Power Requirements For Industrial Motors12-6. Approximate Power Requirements For Farm/Home Equipment Industrial MotorsRating 12-7. Approximate Power Requirements For Contractor EquipmentContractor Starting WattsSingle-Phase Induction Motor Starting Requirements 12-8. Power Required To Start Motor12-9. How Much Power Can Generator Supply? Return To Table Of Contents12-10. Typical Connections To Supply Standby Power Work like a ProCord Lengths for 120 Volt Loads 12-11. Selecting Extension Cord Use Shortest Cord PossibleReturn To Table Of Contents CurrentSECTION 13 − PARTS LIST Figure 13-1. Main Assembly46 FIG Return To Table Of ContentsBig Blue 502, 602 Only Figure 13-1. Main Assembly Figure 13-1. Main Assembly Continued Figure 13-1. Main Assembly Continued CC CV802 551-E Figure 13-2. Control Box Assembly − CC ModelsFigure13-2. Control Box Assembly − CC Models Figure 13-1 Item 802 360-D Figure 13-2. Control Box Assembly − CC Models ContinuedFigure 13-3. Control Box Assembly − CC/CV Models Figure 13-3. Control Box Assembly − CC/CV Models Figure 13-1 Item 802 266-D Figure 13-4. Panel, Front w/Components − CC ModelsFigure 13-4. Panel, Front w/Components − CC Models Figure 13-1 Item Figure 13-4. Panel, Front w/Components − CC Models Continued OptionalFigure 13-5. Panel, Front w/Components − CC/CV Models 802 332-FFigure 13-5. Panel, Front w/Components − CC/CV Models Continued 802 267-B Figure 13-5. Panel, Front w/Components − CC/CV Models ContinuedFigure 13-6. Generator Figure 13-6. Generator Figure 13-1 Item Hardware is common and Figure 13-7. Main Rectifier AssemblyFigure 13-7. Main Rectifier Assembly Figure 13-1 Item not available unless listedCall 1-800-4-A-MILLER for your local Miller distributor Warranty Questions?Service SupportPlease complete and retain with your personal records For ServiceOwner’s Record Always provide Model Name and Serial/Style Number