Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Big Blue 402P Run-In Procedure Using Load Bank, Y Stop engine, from flammables

Models: Big Blue 402P

1 82

Download 82 pages 32.48 Kb

Page 57

11-2. Run-In Procedure Using Load Bank

11-2. Run-In Procedure Using Load Bank

		Y Stop engine.
		Y Do not touch hot exhaust
			pipe, engine parts, or load
			bank/grid.
4		Y Keep exhaust and pipe away
4			from flammables.
			from flammables.
		Y Do not		perform	run-in
		2	procedure at less than 20
			procedure at less than 20
		1	volts weld output and do not
		1	exceed duty cycle or equip-
			ment damage may occur.
		1	Load Bank
		Turn all load bank switches Off. If
		needed, connect load bank to 115
		volts ac wall receptacle or genera-
		tor auxiliary power receptacle.
		2	Welding Generator
		Place A/V range switch in maxi-
		mum position, A/V control in mini-
		mum position, and Output Selector
		switch (if present) in either DC
		position.
		3	Weld Cables
		Connect load bank to generator
		weld output terminals using proper
		size weld cables with			correct
		connectors.		Observe	correct
		polarity.
		Start engine and run for several
	3	minutes.
	3	Set load bank switches and then
		Set load bank switches and then
		adjust generator A/V control so load
		equals rated voltage and current of
		generator (see nameplate, rating
		label, or the specifications section
		in this manual).
		Check generator and load bank
		meters after first five minutes then
		every fifteen minutes to be sure
		generator is loaded properly.
		. Check oil level frequently dur-
			ing run-in; add oil if needed.
		After one hour (minimum) place A/V
		control in minimum position, then
		turn off load bank to remove load.
		Run engine several minutes at no
		load.
		Y Stop engine and let cool.
		4	Engine Exhaust Pipe
		Repeat procedure if wetstacking is
		present.

S-0683

Return To Table Of Contents

OM-491 Page 53

Image 57

Miller Electric Big Blue 402P Run-In Procedure Using Load Bank, Y Stop engine, Y Do not touch hot exhaust, from flammables

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 Mode4-5. Fuel Consumption 4-6. Duty Cycle And Overheating1800 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 OUTPUT6-1. Front Panel Controls For CC Models See Section Return To Table Of ContentsSECTION 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 Contents7-1. Front Panel Controls For CC/CV Models See Section Return To Table Of ContentsSECTION 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 Hot7-4. Remote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control StickExample 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 hMaintenance Label Return To Table Of ContentsOM-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 Off9-9. Troubleshooting Return To Table Of ContentsA. Welding − CC Models B. Welding − CC/CV Models TroubleRemedy 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 ContentsSECTION 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 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 LISTReturn To Table Of Contents Big Blue 502, 602 Only46 FIG Figure 13-1. Main Assembly Figure 13-1. Main Assembly Continued CC CV Figure 13-1. Main Assembly ContinuedFigure 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 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 13-5. Panel, Front w/Components − CC/CV Models Continued Figure 13-6. Generator802 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