Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Big Blue 402P, Big Blue 602P manual OM-491 Page, Return To Table Of Contents

Models: Big Blue 402P

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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 Mode4-5. Fuel Consumption 4-6. Duty Cycle And Overheating1800 RPM IDLE 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 OUTPUT6-1. Front Panel Controls For CC Models See Section Return To Table Of ContentsSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 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 Page7-1. Front Panel Controls For CC/CV Models See Section Return To Table Of ContentsSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 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 Hot7-4. Remote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control StickExample Combination Remote Amperage Control TIG 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 hMaintenance Label Return To Table Of ContentsOM-491 Page 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 Off9-9. Troubleshooting Return To Table Of ContentsA. Welding − CC Models B. Welding − CC/CV Models TroubleRemedy 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 PageSECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding GeneratorReturn To Table Of Contents Return To Table Of Contents OM-491 Page215 304-A Figure 10-2. Circuit Diagram For CC/CV Welding Generator Return To Table Of ContentsOM-491 Page Return To Table Of Contents OM-491 Page215 305-A 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 AssemblyReturn To Table Of Contents Big Blue 502, 602 Only46 FIG Figure 13-1. Main Assembly Figure 13-1. Main Assembly Continued Figure 13-1. Main Assembly Continued CC CVFigure 13-2. Control Box Assembly − CC Models Figure13-2. Control Box Assembly − CC Models Figure 13-1 Item802 551-E Figure 13-2. Control Box Assembly − CC Models Continued Figure 13-3. Control Box Assembly − CC/CV Models802 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 13-4. Panel, Front w/Components − CC Models Figure 13-1 Item802 266-D 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 Figure 13-5. Panel, Front w/Components − CC/CV Models Continued Figure 13-6. Generator802 267-B 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