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Miller Electric Big Blue 602P manual Typical Connections To Supply Standby Power, Work like a Pro

Models: Big Blue 402P

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12-10. Typical Connections To Supply Standby Power

12-10. Typical Connections To Supply Standby Power

Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

1

Utility

Electrical

Service

2

Transfer Switch

5

Essential

Loads

3

Fused

Disconnect

Switch

(If Required)

4

Welding

Generator

Output

YHave only qualified persons perform these connections according to all applicable codes and safety practic- es.

YProperly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

.Customer-supplied equipment is re- quired if generator will supply standby power during emergencies or power out- ages.

1Utility Electrical Service

2Transfer Switch (Double-Throw)

Switch transfers the electrical load from electric utility service to the generator. Trans- fer load back to electric utility when service is restored.

Install correct switch (customer-supplied). Switch rating must be same as or greater than the branch overcurrent protection.

3 Fused Disconnect Switch

Install correct switch (customer-supplied) if required by electrical code.

4 Welding Generator Output

Generator output voltage and wiring must be consistent with regular (utility) system volt- age and wiring.

Connect generator with temporary or perma- nent wiring suitable for the installation.

Turn off or unplug all equipment connected to generator before starting or stopping engine. When starting or stopping, the engine has low speed which causes low voltage and frequency.

5 Essential Loads

Generator output may not meet the electrical requirements of the premises. If generator does not produce enough output to meet all requirements, connect only essential loads (pumps, freezers, heaters, etc. − See Sec- tion 12-4).

Notes

Work like a Pro!

Pros weld and cut safely. Read the safety rules at the beginning of this manual.

OM-491 Page 60

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Miller Electric Big Blue 602P, Big Blue 402P, Big Blue 502P Typical Connections To Supply Standby Power, Work like a Pro

Contents

Big BlueR 402P, 502P, 602P OM-491Processes DescriptionFrom Miller to You TABLE OF CONTENTS SECTION 5 − INSTALLATIONTABLE OF CONTENTS OPTIONS AND ACCESSORIESWARRANTY SECTION1-1. Symbol Usage 1-2. Arc Welding HazardsSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Means “Note” not safety related1-3. Engine Hazards BATTERY EXPLOSION can BLINDReturn To Table Of Contents WELDING can cause fire or explosion1-5. Additional Symbols For Installation, Operation, And Maintenance 1-4. Compressed Air HazardsSTEAM AND HOT COOLANT can burn ENGINE EXHAUST GASES can kill1-7. Principal Safety Standards 1-6. California Proposition 65 Warnings1-8. EMF Information READ INSTRUCTIONS2-1. Signification des symboles SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION2-2. Dangers relatifs au soudage à l’arc UN CHOC ÉLECTRIQUE peut tuer2-3. Dangers existant en relation avec le moteur LE SOUDAGE peut provoquer un in- cendie ou une explosionDES PARTICULES VOLANTES peuvent blesser les yeux DES PIÈCES CHAUDES peuvent provoquer des brûlures graves2-4. Dangers liés à l’air comprimé L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLEDES ORGANES MOBILES peuvent provoquer des blessures LA CHALEUR DU MOTEUR peut pro- voquer un incendie2-6. Principales normes de sécurité 2-7. Information sur les champs électromagnétiquesLE SURCHAUFFEMENT peut endom- mager le moteur électrique LES ÉTINCELLES VOLANTES ris- quent de provoquer des blessuresSECTION 4 − SPECIFICATIONS 3-1. Symbols And DefinitionsSECTION 3 − 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−Max4-4. Volt-Ampere Curves For CC/CV Models A. Stick ModeB. MIG Mode C. TIG Mode4-6. Duty Cycle And Overheating 4-5. Fuel Consumption1800 RPM IDLE 4-7. AC Generator Power Curve 4-8. Optional Three-Phase Generator CurvesA. 12 kVA/kW Single-Phase AC Output No Weld Load B. 20 kVA/kW Three-Phase AC Output No Weld LoadSECTION 5 − INSTALLATION 5-1. Installing Welding GeneratorReturn To Table Of Contents Movement5-2. Mounting Welding Generator Using Mounting BracketsSupporting The Unit Inadequate support5-3. Using Lifting Eye 5-4. Installing Exhaust PipeReturn To Table Of Contents Y Stop engine and let cool5-5. Activating The Dry Charge Battery If Applicable When electrolyte is low, addReturn To Table Of Contents Y Read and follow all instruc5-6. Connecting The Battery Reinstall cover after connecting batteryReturn To Table Of Contents Y Connect Negative − Cable Last5-7. Engine Prestart Checks Check radiator coolant level when fluid is low in recovery tankCoolant Recovery Tank Return To Table Of Contents5-8. Connecting To Weld Output Terminals 5-9. Selecting Weld Cable Sizes5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models 24 VOLTS ACREMOTE OUTPUTReturn To Table Of Contents 6-1. Front Panel Controls For CC Models See SectionSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 6-2. Description Of Front Panel Controls For CC Models See Section Engine Indicator LightsY Stop engine and fix trouble if Battery Charging light goes on Y Do not switch under load6-3. Remote Amperage Control On CC Models Optional 6-4. Weld Control/Arc Condition Information LabelReturn To Table Of Contents Set weld controls as shown toReturn To Table Of Contents OM-491 PageReturn To Table Of Contents 7-1. Front Panel Controls For CC/CV Models See SectionSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-2. Description Of Front Panel Controls For CC/CV Models See Section Engine Indicator LightsY Stop engine and fix trouble if Battery Charging light goes on Y Do not switch under load7-3. Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsProcess/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 SECTION 8 − OPERATING AUXILIARY EQUIPMENT 8-1. 120 Volt And 240 Volt Receptaclesrized Service Agent power8-2. Connecting To Optional Three-Phase Generator CC/CV Models Only Single-Phase Power ConnectionSingle-Phase Generator Power Three-Phase Power Connection8-3. Optional Generator Power Receptacles Generator power is not af- fected by weld outputReturn To Table Of Contents European ReceptacleSECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Routine MaintenanceEvery 8 h Every 50 hEvery 400 h Every 500 hEvery 800 h Every 1000 hReturn To Table Of Contents Maintenance LabelOM-491 Page 9-3. Servicing Air Cleaner by the warrantyThe air cleaner primary element can To clean air filter9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler Y Stop engine and let coolY Stop engine and let cool 802 160-E / Ref. 2029-5. Adjusting Engine Speed Models With Automatic Idle Optional Idle Speed AdjustmentWeld/Power Speed Adjustment Return To Table Of Contents9-6. Servicing Fuel And Lubrication Systems Y Stop engine and let coolTo change oil and filter To drain water from fuel system9-7. Overload Protection When a circuit breaker or fusemore serious problem exists Service Agent9-8. Diagnosing Causes Of Engine Fault Shutdowns Pre-Start Diagnostic ChecksDiagnostic 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 C. Standard Generator Power D. Optional Three-Phase Generator Power CC/CV Models OnlyReturn To Table Of Contents E. EngineEngine starts, but stops when Magnetic Return To Table Of Contents OM-491 PageFigure 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 SECTION 11 − RUN-IN PROCEDURE 11-1. Wetstacking11-2. Run-In Procedure Using Load Bank procedure at less thanReturn To Table Of Contents Y Stop engine11-3. Run-In Procedure Using Resistance Grid procedure at less thanStop engine Y Do not touch hot exhaustSECTION 12 − GENERATOR POWER GUIDELINES 12-1. Selecting Equipment12-2. Grounding Generator To Truck Or Trailer Frame has this symbol12-3. Grounding When Supplying Building Systems 12-4. How Much Power Does Equipment Require?earth ground if supplying Use ground device as stated in electrical codes12-5. Approximate Power Requirements For Industrial Motors 12-6. Approximate Power Requirements For Farm/Home EquipmentReturn To Table Of Contents Industrial Motors12-7. Approximate Power Requirements For Contractor Equipment ContractorRating Starting Watts12-8. Power Required To Start Motor 12-9. How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements Return To Table Of Contents12-10. Typical Connections To Supply Standby Power Work like a Pro12-11. Selecting Extension Cord Use Shortest Cord Possible Return To Table Of ContentsCord Lengths for 120 Volt Loads CurrentSECTION 13 − PARTS LIST Figure 13-1. Main AssemblyBig Blue 502, 602 Only Return To Table Of Contents46 FIG Figure 13-1. Main Assembly Figure 13-1. Main Assembly Continued Figure 13-1. Main Assembly Continued CC CVFigure13-2. 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 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 13-6. 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 13-7. Main Rectifier Assembly Figure 13-1 ItemHardware is common and not available unless listedWarranty Questions? ServiceCall 1-800-4-A-MILLER for your local Miller distributor SupportFor Service Owner’s RecordPlease complete and retain with your personal records Always provide Model Name and Serial/Style Number