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Miller Electric Big Blue 602P Installation, Installing Welding Generator, Movement, Location

Models: Big Blue 402P

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SECTION 5 − INSTALLATION

SECTION 5 − INSTALLATION

5-1. Installing Welding Generator

Movement

OR

OR

Location

OR

OR

Grounding

1

GND/PE2

YAlways securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.

YAlways ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards.

YIf unit does not have GFCI re- ceptacles, use GFCI-protected extension cord.

.See Section 5-2for mounting in- formation.

Grounding:

1Equipment Grounding Terminal (On Front Panel)

2Grounding Cable (Not Supplied)

3Metal Vehicle Frame

Connect cable from equipment ground terminal to metal vehicle frame. Use #10 AWG or larger insu- lated copper wire.

Electrically bond generator frame to vehicle frame by metal-to-metal contact.

3Y Bed liners, shipping skids, and some running gears insulate the welding generator from the vehicle frame. Always connect a ground wire from the generator equipment grounding termi- nal to bare metal on the vehicle frame as shown.

Airflow Clearance

18in

(460 mm)

18 in

18 in(460 mm)

(460 mm)

18 in

18 in(460 mm)

(460 mm)

install3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274

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OM-491 Page 15

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Miller Electric Big Blue 602P Installation, Installing Welding Generator, Movement, Location, Grounding, Airflow Clearance

Contents

Description Big BlueR 402P, 502P, 602POM-491 ProcessesFrom Miller to You SECTION 5 − INSTALLATION TABLE OF CONTENTSSECTION TABLE OF CONTENTSOPTIONS AND ACCESSORIES WARRANTYMeans “Note” not safety related 1-1. Symbol Usage1-2. Arc Welding Hazards SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGWELDING can cause fire or explosion 1-3. Engine HazardsBATTERY EXPLOSION can BLIND Return To Table Of ContentsENGINE EXHAUST GASES can kill 1-5. Additional Symbols For Installation, Operation, And Maintenance1-4. Compressed Air Hazards STEAM AND HOT COOLANT can burnREAD INSTRUCTIONS 1-7. Principal Safety Standards1-6. California Proposition 65 Warnings 1-8. EMF InformationUN CHOC ÉLECTRIQUE peut tuer 2-1. Signification des symbolesSECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 2-2. Dangers relatifs au soudage à l’arcDES PIÈCES CHAUDES peuvent provoquer des brûlures graves 2-3. Dangers existant en relation avec le moteurLE SOUDAGE peut provoquer un in- cendie ou une explosion DES PARTICULES VOLANTES peuvent blesser les yeuxLA CHALEUR DU MOTEUR peut pro- voquer un incendie 2-4. Dangers liés à l’air compriméL’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE DES ORGANES MOBILES peuvent provoquer des blessuresLES ÉTINCELLES VOLANTES ris- quent de provoquer des blessures 2-6. Principales normes de sécurité2-7. Information sur les champs électromagnétiques LE SURCHAUFFEMENT peut endom- mager le moteur électriqueReturn To Table Of Contents SECTION 4 − SPECIFICATIONS3-1. Symbols And Definitions SECTION 3 − DEFINITIONS4-2. Dimensions, Weights, And Operating Angles 4-1. Weld, Power, And Engine Specifications300−Max 4-3. Volt-Ampere Curves For CC ModelsC. TIG Mode 4-4. Volt-Ampere Curves For CC/CV ModelsA. Stick Mode B. MIG Mode4-6. Duty Cycle And Overheating 4-5. Fuel Consumption1800 RPM IDLE B. 20 kVA/kW Three-Phase AC Output No Weld Load 4-7. AC Generator Power Curve4-8. Optional Three-Phase Generator Curves A. 12 kVA/kW Single-Phase AC Output No Weld LoadMovement SECTION 5 − INSTALLATION5-1. Installing Welding Generator Return To Table Of ContentsInadequate support 5-2. Mounting Welding GeneratorUsing Mounting Brackets Supporting The UnitY Stop engine and let cool 5-3. Using Lifting Eye5-4. Installing Exhaust Pipe Return To Table Of ContentsY Read and follow all instruc 5-5. Activating The Dry Charge Battery If ApplicableWhen electrolyte is low, add Return To Table Of ContentsY Connect Negative − Cable Last 5-6. Connecting The BatteryReinstall cover after connecting battery Return To Table Of ContentsReturn To Table Of Contents 5-7. Engine Prestart ChecksCheck radiator coolant level when fluid is low in recovery tank Coolant Recovery Tank5-9. Selecting Weld Cable Sizes 5-8. Connecting To Weld Output TerminalsOUTPUT 5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models24 VOLTS AC REMOTEReturn To Table Of Contents 6-1. Front Panel Controls For CC Models See SectionSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS Y Do not switch under load 6-2. Description Of Front Panel Controls For CC Models See SectionEngine Indicator Lights Y Stop engine and fix trouble if Battery Charging light goes onSet weld controls as shown to 6-3. Remote Amperage Control On CC Models Optional6-4. Weld Control/Arc Condition Information Label Return To Table Of ContentsOM-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 Y Do not switch under load 7-2. Description Of Front Panel Controls For CC/CV Models See SectionEngine Indicator Lights Y Stop engine and fix trouble if Battery Charging light goes onswitch is in an Electrode Hot 7-3. Process/Contactor Switch On CC/CV ModelsProcess/Contactor Switch Settings Process/Contactor SwitchExample Combination Remote Amperage Control Stick 7-4. Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control TIG power SECTION 8 − OPERATING AUXILIARY EQUIPMENT8-1. 120 Volt And 240 Volt Receptacles rized Service AgentThree-Phase Power Connection 8-2. Connecting To Optional Three-Phase Generator CC/CV Models OnlySingle-Phase Power Connection Single-Phase Generator PowerEuropean Receptacle 8-3. Optional Generator Power ReceptaclesGenerator power is not af- fected by weld output Return To Table Of ContentsEvery 50 h SECTION 9 − MAINTENANCE & TROUBLESHOOTING9-1. Routine Maintenance Every 8 hEvery 1000 h Every 400 hEvery 500 h Every 800 hReturn To Table Of Contents Maintenance LabelOM-491 Page To clean air filter 9-3. Servicing Air Cleanerby the warranty The air cleaner primary element can802 160-E / Ref. 202 9-4. Inspecting And Cleaning Optional Spark Arrestor MufflerY Stop engine and let cool Y Stop engine and let coolReturn To Table Of Contents 9-5. Adjusting Engine SpeedModels With Automatic Idle Optional Idle Speed Adjustment Weld/Power Speed AdjustmentTo drain water from fuel system 9-6. Servicing Fuel And Lubrication SystemsY Stop engine and let cool To change oil and filterService Agent 9-7. Overload ProtectionWhen a circuit breaker or fuse more serious problem existsBattery Charging, Fuel, And Temperature Lights Off 9-8. Diagnosing Causes Of Engine Fault ShutdownsPre-Start Diagnostic Checks Diagnostic Checks While RunningReturn To Table Of Contents 9-9. TroubleshootingA. Welding − CC Models Trouble B. Welding − CC/CV ModelsRemedy E. Engine C. Standard Generator PowerD. Optional Three-Phase Generator Power CC/CV Models Only Return To Table Of ContentsEngine 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 PROCEDUREY Stop engine 11-2. Run-In Procedure Using Load Bankprocedure at less than Return To Table Of ContentsY Do not touch hot exhaust 11-3. Run-In Procedure Using Resistance Gridprocedure at less than Stop enginehas this symbol SECTION 12 − GENERATOR POWER GUIDELINES12-1. Selecting Equipment 12-2. Grounding Generator To Truck Or Trailer FrameUse ground device as stated in electrical codes 12-3. Grounding When Supplying Building Systems12-4. How Much Power Does Equipment Require? earth ground if supplyingIndustrial Motors 12-5. Approximate Power Requirements For Industrial Motors12-6. Approximate Power Requirements For Farm/Home Equipment Return To Table Of ContentsStarting Watts 12-7. Approximate Power Requirements For Contractor EquipmentContractor RatingReturn To Table Of Contents 12-8. Power Required To Start Motor12-9. How Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsWork like a Pro 12-10. Typical Connections To Supply Standby PowerCurrent 12-11. Selecting Extension Cord Use Shortest Cord PossibleReturn To Table Of Contents Cord Lengths for 120 Volt LoadsFigure 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 not available unless listed Figure 13-7. Main Rectifier AssemblyFigure 13-7. Main Rectifier Assembly Figure 13-1 Item Hardware is common andSupport Warranty Questions?Service Call 1-800-4-A-MILLER for your local Miller distributorAlways provide Model Name and Serial/Style Number For ServiceOwner’s Record Please complete and retain with your personal records