Miller Electric Big Blue 502P Owner's Manual

Big Blue 402P, 502P, 602POM-491 190 355LMay 2000Visit our website atwww.MillerWelds.comProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and GougingS

OM-491 Page 6Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étince

OM-491 Page 7DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvemen

OM-491 Page 8LE RAYONNEMENT HAUTE FRÉ-QUENCE (H.F.) risque de provoquerdes interférences. Le rayonnement haute fréquence (H.F.) peutprovoquer des int

OM-491 Page 9SECTION 2 − DEFINITIONS2-1. Symbols And DefinitionsStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineStarting Aid Battery (Engine)

OM-491 Page 103-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated WeldingOutputMaximumOpen-CircuitVoltageAuxiliary Power Ratin

OM-491 Page 113-3. Volt-Ampere Curves For CC ModelsRef. 193 017The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilit

OM-491 Page 123-4. Volt-Ampere Curves for CC/CV Models194 364 / 194 365 / 194 366The volt-ampere curves show theminimum and maximum voltageand amperag

OM-491 Page 133-5. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.193 0930 50 100 150 200 250 300 350 400 450 500DC WELD AM

OM-491 Page 143-7. AC Auxiliary Power Curve193 018The ac power curve shows the aux-iliary power in amperes available atthe 120 and 240 volt receptacle

OM-491 Page 15SECTION 4 − INSTALLATION4-1. Installing Welding Generator (See Sections 4-2 And 4-3)install1 12/99* − Ref. 800 652 / Ref. 800 477-A / 15

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-491 Page 164-3. Mounting Welding GeneratorRef. 190 250-A / Ref. 802 169-C Do not weld on base. Weld-ing on base can cause fueltank fire or explosi

OM-491 Page 174-5. Activating The Dry Charge Battery (If Applicable)Remove battery from unit.1 Eye Protection − SafetyGlasses Or Face Shield2 Rubber G

OM-491 Page 184-6. Connecting The Battery1/2 in−+ Connect Negative (−) Cable Last.Tools Needed:ST-802 168-D / Ref. ST-191 631-C / S-0756-CNotes

OM-491 Page 194-7. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break-in

OM-491 Page 204-8. Connecting To Weld Output Terminals Ref. 802 169-C Stop engine.1 Positive (+) Weld OutputTerminal2 Negative (−) Weld Output Ter-mi

OM-491 Page 214-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC ModelsRef. 154 862-A / 048 720-K / 802 160-B1 Remote Amperage AdjustRec

OM-491 Page 224-11. Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsSocket* Socket Information24 VOLTS ACA 24 volts ac. Protected by circuitbre

OM-491 Page 23SECTION 5 − OPERATING WELDING GENERATOR − CC MODELS5-1. Front Panel Controls For CC Models (See Section 5-2)17191 631-C / 802 311-A15 16

OM-491 Page 245-2. Description Of Front Panel Controls For CC Models (See Section 5-1)Engine Starting Controls1 Magnetic Shutdown SwitchUse switch dur

OM-491 Page 255-3. Remote Amperage Control On CC Models (Optional)1 Remote Amperage AdjustReceptacle RC13Connect optional remote control toRC13 (see S

The following terms areused interchangeablythroughout this manual:Stick = SMAWTIG = GTAWMIG = GMAWCALIFORNIAProposition 65WarningDiesel engine exhaust

OM-491 Page 26SECTION 6 − OPERATING WELDING GENERATOR − CC/CV MODELS6-1. Front Panel Controls For CC/CV Models (See Section 6-2)17192 895-A / 802 311-

OM-491 Page 276-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1)Engine Starting Controls1 Magnetic Shutdown SwitchUse switch

OM-491 Page 286-3. Process/Contactor Switch On CC/CV Models11 Process/Contactor Switch Weld output terminals are en-ergized when Process/Con-tactor s

OM-491 Page 296-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see Se

OM-491 Page 30SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. 120 Volt And 240 Volt Receptacles21 120 V 20 A AC GFCIReceptacle GFCI12 240 V 20 A AC Twis

OM-491 Page 317-2. Connecting To Optional Auxiliary Power Plant (CC/CV Models Only)Ref. 197 399 / 802 332-B Place Process/Contactor switchin Electrod

OM-491 Page 32SECTION 8 − MAINTENANCE & TROUBLESHOOTING Follow the storage procedure in the engine owner’s manual if the unit will not be used for

OM-491 Page 33400 hChange Oil. SeeSection 8-6.Change OilFilter. SeeSection 8-6.Check RadiatorFluid Level. SeeSection 4-7.Change FuelFilters. SeeSectio

OM-491 Page 348-2. Maintenance Label

OM-491 Page 358-3. Servicing Air Cleaner Ref. 187 602-A / 801 964 / Ref. 191 631-C Stop engine. Do not run engine without aircleaner or with dirty e

OM-491 Page 368-5. Adjusting Engine Speed802 168-C / 802 229-A / Ref. 191 631-C Stop engine and let cool.Engine speed is factory set andshould not re

OM-491 Page 378-6. Servicing Fuel And Lubrication Systems802 170-A / Ref. 802 168-B / Ref. 801 434 Stop engine and let cool. After servicing, start

OM-491 Page 388-7. Overload Protection Stop engine. When a circuit breaker or fuseopens, it usually indicates amore serious problem exists.Contact F

OM-491 Page 398-8. Diagnosing Causes Of Engine Fault ShutdownsRef. 191 631-CUse the front panel engine lights tohelp determine the cause of an au-tom

OM-491 Page 408-9. TroubleshootingA. Welding − CC ModelsTrouble RemedyNo weld output; auxiliary power outputokay.Check position of Ampere Range switch

OM-491 Page 41B. Welding − CC/CV ModelsTrouble RemedyNo weld output; auxiliary power outputokay.Place Process/Contactor switch in a Electrode Hot posi

OM-491 Page 42C. Standard Auxiliary PowerTrouble RemedyNo auxiliary power output; weld outputokay.Reset receptacle circuit breakers.No auxiliary power

OM-491 Page 43Trouble RemedyEngine starts, but stops when MagneticShutdown switch is released.When starting engine, continue holding Magnetic Shutdown

OM-491 Page 44SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For CC Welding Generator

OM-491 Page 45200 130

OM-491 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGrom _nd_11/981-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith

OM-491 Page 46 Figure 9-2. Circuit Diagram For CC/CV Welding Generator

OM-491 Page 47194 008-C

OM-491 Page 48SECTION 10 − RUN-IN PROCEDURErun_in1 6/9610-1. Wetstacking1 Welding GeneratorRun diesel engines near rated out-put during run-in period

OM-491 Page 4910-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust

OM-491 Page 5010-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep ex

OM-491 Page 51SECTION 11 − AUXILIARY POWER GUIDELINES11-1. Selecting Equipmentaux_pwr 2/99 − Ref. ST-159 730 / ST-800 5771 Auxiliary Power Receptacles

OM-491 Page 5211-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulated

OM-491 Page 5311-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 30

OM-491 Page 5411-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-491 Page 5511-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-491 Page 2Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flyin

OM-491 Page 5611-10. Typical Connections To Supply Standby PowerS-0405-A1 Power Company ServiceMeter2 Main and Branch OvercurrentProtection3 Double-Po

OM-491 Page 5711-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, us

OM-491 Page 58SECTION 12 − PARTS LIST Hardware is common andnot available unless listed.1234567891013141516171819202122232425262930313233349798991001

OM-491 Page 59802 265-F3536373839424345464748495053−(Fig. 12-6)54606162636465666768697071727374757677787980828384858990919293−(Fig. 12-2 or 12-3)94514

OM-491 Page 60DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 189 824 PANEL, gen LH 1. . . . . . . . . . . . . . . . . . . .

OM-491 Page 61DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity44 189 245 TANK, fuel 23gal (consisting of) 1. . . . .

OM-491 Page 62DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity87 191 500 LINE, fuel supply 1. . . . . . . . . . . . .

OM-491 Page 63802 278-B1234561478910111213Figure 12-2. Control Box Assembly − CC ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Control Box Asse

OM-491 Page 64802 360123456789101112Figure 12-3. Control Box Assembly − CC/CV ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-3. Control Box Assembl

OM-491 Page 65 Hardware is common andnot available unless listed.802 266-C414243Figure 12-4. Panel, Front w/Components − CC ModelsDescriptionPartNo.D

OM-491 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely in

OM-491 Page 66DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-4. Panel, Front w/Components − CC Models (Continued)QuantityRC6 192 558 HARNESS, range (cons

OM-491 Page 67 Hardware is common andnot available unless listed.802 332-D525354Figure 12-5. Panel, Front w/Components − CC/CV ModelsDescriptionPartN

OM-491 Page 68DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity193 159 HARNESS, front panel

OM-491 Page 69DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity46 FUEL 191 242 GAUGE, fuel e

OM-491 Page 70DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-6. Generator (Figure 12-1 Item 53)Quantity1 132 053 SCREW, 375-16 x 1.50hexhd pln gr 5pld 6.

OM-491 Page 71 Hardware is common andnot available unless listed.802 279123465789Figure 12-7. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs.ItemN

OM-491 Page 72Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 4/00Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA © 2000 Miller Electric Mfg. Co. 1/00Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-491 Page 4H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunic

OM-491 Page 5SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom _nd_fre 11/981-1. Signification des symbolesSignifie Mise en garde ! Soyez