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Miller Electric Big Blue 502P manual Selecting Extension Cord Use Shortest Cord Possible, Current

Models: Big Blue 402P

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12-11. Selecting Extension Cord (Use Shortest Cord Possible)

12-11. Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 Volt Loads

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

			Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
Current	Load (Watts)	4			6		8	10	12		14
(Amperes)	Load (Watts)	4			6		8	10	12		14
(Amperes)

5	600					350	(106)	225 (68)	137 (42)		100 (30)

7	840			400	(122)	250 (76)		150 (46)	100 (30)		62 (19)

10	1200	400 (122)		275 (84)		175 (53)		112 (34)	62 (19)		50 (15)

15	1800	300 (91)		175 (53)		112 (34)		75 (23)	37 (11)		30 (9)

20	2400	225 (68)		137 (42)		87	(26)	50 (15)	30 (9)

25	3000	175 (53)		112 (34)		62	(19)	37 (11)

30	3600	150 (46)		87	(26)	50	(15)	37 (11)

35	4200	125 (38)		75	(23)	50	(15)

40	4800	112 (34)		62	(19)	37 (11)

45	5400	100 (30)		62	(19)

50	6000	87 (26)		50	(15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

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

			Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
Current	Load (Watts)	4		6		8	10	12		14
(Amperes)	Load (Watts)	4		6		8	10	12		14
(Amperes)

5	1200				700	(213)	450 (137)	225 (84)		200 (61)

7	1680			800 (244)	500	(152)	300 (91)	200 (61)		125 (38)

10	2400	800 (244)		550 (168)	350	(107)	225 (69)	125 (38)		100 (31)

15	3600	600 (183)		350 (107)	225 (69)		150 (46)	75 (23)		60 (18)

20	4800	450 (137)		275 (84)	175 (53)		100 (31)	60 (18)

25	6000	350 (107)		225 (69)	125 (38)		75 (23)

30	7000	300 (91)		175 (53)	100 (31)		75 (23)

35	8400	250 (76)		150 (46)	100 (31)

40	9600	225 (69)		125 (38)	75	(23)

45	10,800	200 (61)		125 (38)

50	12,000	175 (53)		100 (31)

*Conductor size is based on maximum 2% voltage drop

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OM-491 Page 61

Image 65

Miller Electric Big Blue 502P manual Selecting Extension Cord Use Shortest Cord Possible, Cord Lengths for 120 Volt Loads

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 Mode1800 RPM IDLE 4-5. Fuel Consumption4-6. Duty Cycle And Overheating 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 OUTPUTSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 6-1. Front Panel Controls For CC Models See SectionReturn To Table Of Contents 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 ContentsSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models See SectionReturn To Table Of Contents 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 HotExample Combination Remote Amperage Control TIG 7-4. Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control Stick 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 hOM-491 Page Maintenance LabelReturn To Table Of Contents 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 OffA. Welding − CC Models 9-9. TroubleshootingReturn To Table Of Contents Remedy B. Welding − CC/CV ModelsTrouble 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 ContentsReturn 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 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 LIST46 FIG Return To Table Of ContentsBig Blue 502, 602 Only Figure 13-1. Main Assembly Figure 13-1. Main Assembly Continued CC CV Figure 13-1. Main Assembly Continued802 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 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 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 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