Miller Electric Big Blue 502P Owner's Manual
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Miller Electric Big Blue 502P Owner's Manual

Miller Electric Big Blue 502P Owner's Manual

Miller electric owner's manual welding generator big blue 502p, big blue 602p
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Big Blue 502P, 602P
R
OM-491
190 355
January 1999
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator

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  • Page 1 Visit our website at www.Miller- Welds.com Big Blue 502P, 602P OM-491 190 355 January 1999 Processes Stick (SMAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator...
  • Page 2 ISO 9001 Quality service information for your particular model System Standard. are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.

  • Page 3: Table Of Contents

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING WARNING SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2.

  • Page 6: Engine Hazards

    WELDING can cause fire or explo- sion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    MOVING PARTS can cause injury. D Keep away from fans, belts, and rotors. D Keep all doors, panels, covers, and guards closed and securely in place. D Stop engine before installing or connecting unit. D Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary.

  • Page 8: Principal Safety Standards

    H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. D The user is responsible for having a qualified electrician prompt- ly correct any interference problem resulting from the installa- tion.

  • Page 9: Section 1 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANT 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. Signifie NOTA ;...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. LE SOUDAGE peut provoquer un in- cendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements protection. D Arrêter le moteur avant d’installer ou brancher l’appareil. D Demander seulement à...

  • Page 12: Principales Normes De Sécurité

    LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences. D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs. D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.

  • Page 13: Section 2 − Definitions

    SECTION 2 − DEFINITIONS 2-1. Symbols And Definitions Stop Engine Starting Aid Check Injectors/ Pump Positive Amperes Engine Stick (SMAW) Welding Time Three Phase SECTION 3 − SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Weld Welding Rated Welding Output Mode Output Range 400 A, 40 Volts DC,...

  • Page 14: Dimensions, Weights, And Operating Angles

    3-2. Dimensions, Weights, And Operating Angles Dimensions 60 in (1524 mm) Height (to top of muffler) 28-1/2 in (724 mm) (mtg. brackets turned in) Width 30-3/4 in (781 mm) (mtg. brackets turned out) Depth 64-7/16 in (1637 mm) 64-7/16 in (1637 mm) 55-7/8 in (1419 mm) 9-1/2 in (241 mm) 27-1/2 in (699 mm)

  • Page 15: Fuel Consumption

    3-4. Fuel Consumption 1800 RPM 50 100 150 200 250 300 350 400 450 500 DC WELD AMPERES AT 100% DUTY CYCLE 3-5. Duty Cycle And Overheating 100% Duty Cycle At 400 Amperes Continuous Welding The curve shows typical fuel use under weld or power loads.

  • Page 16: Ac Auxiliary Power

    3-6. AC Auxiliary Power AC AMPERES IN 240V MODE AC AMPERES IN 120V MODE OM-491 Page 12 The ac power curve shows the aux- iliary power in amperes available at the 120 and 240 volt receptacles. 193 018...

  • Page 17: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Installing Welding Generator (See Sections 4-2 And 4-3) Movement Grounding Electrically bond generator frame to vehicle frame by metal-to-metal contact. 4-2. Using Lifting Eye Airflow Clearance 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in 18 in...

  • Page 18: Mounting Welding Generator

    4-3. Mounting Welding Generator Tools Needed: 9/16 in 4-4. Installing Muffler Tools Needed: 1/2 in OM-491 Page 14 Y Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.

  • Page 19: Activating The Dry Charge Battery (If Applicable)

    4-5. Activating The Dry Charge Battery (If Applicable) 5 A For 30 Minutes 30 A For 12 Minutes − Remove battery from unit. Eye Protection − Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum).

  • Page 20: Connecting The Battery

    4-6. Connecting The Battery Y Connect Negative (−) Cable Last. − Tools Needed: 1/2 in ST-802 168-A / Ref. ST-191 631-A / S-0756-C OM-491 Page 16...

  • Page 21: Engine Prestart Checks

    4-7. Engine Prestart Checks Check radiator coolant level when fluid is low in recovery tank. Capacity: w/Overflow Tank 12 qt (11.4L) Check all engine fluids daily. Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if fuel level or oil pressure is too low, or coolant temperature is too high.

  • Page 22: Connecting To Weld Output Terminals

    4-8. Connecting To Weld Output Terminals 4-9. Selecting Weld Cable Sizes 100 ft (30 m) Or Less Welding Amperes Amperes 10 − 60% 60 − 100% Duty Cycle Duty Cycle *Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for the mm equivalent weld cable sizes.

  • Page 23: Connecting To Remote Amperage Adjust Receptacle Rc13

    4-10. Connecting To Remote Amperage Adjust Receptacle RC13 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-3). Ref. 154 862-A / 048 720-K / 802 160-A OM-491 Page 19...

  • Page 24: Section 5 − Operating The Welding Generator

    SECTION 5 − OPERATING THE WELDING GENERATOR 5-1. Front Panel Controls (See Section 5-2) 10 11 191 631-A / 802 160-A OM-491 Page 20...

  • Page 25: Description Of Front Panel Controls (See Section 5-1)

    5-2. Description Of Front Panel Controls (See Section 5-1) Engine Starting Controls Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure or fuel level is too low or coolant tem- perature is too high. Starting Aid Switch Use switch to energize port heater for cold weather starting (see starting instructions fol-...

  • Page 26: Remote Control (Optional)

    5-3. Remote Control (Optional) Example: Combination Remote Amperage Control (Stick) Set Switches Set Range OM-491 Page 22 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 4-10). In Example: Range = 125 to 320 A DC Percentage Of Range = 50% Max = About 223 A DC (50% of 125 to 320) Max (223 A DC)

  • Page 27: Section 6 − Operating Auxiliary Equipment

    SECTION 6 − OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt And 240 Volt Duplex Receptacles 120 V 20 A AC GFCI Recep- tacle GFCI1 240 V 20 A AC Receptacle Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, GFCI Reset button pops...

  • Page 28: Section 7 − Maintenance & Troubleshooting

    SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance Wipe Spills. Clean Air Filter. See Section 7-3. Check Radiator Fluid Level. See Section 4-7. OM-491 Page 24 Recycle engine fluids. Coolant Check Fluid Full Levels. See Section 4-7. Full 50 h 100 h Clean And Tighten...
  • Page 29 Change Fuel Filters. See Section 7-6. Blow Out Or Vacuum Inside. During Heavy Service, Clean Monthly. Check Valve Clearance.* 500 h Repair Or Replace Damaged Cables. 800 h Clean/Set Injectors.* 1000 h FUEL SLUDGE Service Welding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Drain Sludge From Fuel...

  • Page 30: Maintenance Label

    7-2. Maintenance Label OM-491 Page 26...

  • Page 31: Servicing Air Cleaner

    7-3. Servicing Air Cleaner Blow 7-4. Inspecting And Cleaning Optional Spark Arrestor Muffler Tools Needed: 3/8 in Inspect Y Stop engine. Y Do not run engine without air cleaner or with dirty element. Evacuator Valve Dust Cap Element Housing Clean or replace element if dirty or damaged.

  • Page 32: Adjusting Engine Speed

    7-5. Adjusting Engine Speed Engine RPM (Hz) Speed (No Load) 1850 (61) Weld/Power Maximum OM-491 Page 28 Y Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer. See table for proper no load speed.

  • Page 33: Servicing Fuel And Lubrication Systems

    7-6. Servicing Fuel And Lubrication Systems Y Stop engine and let cool. Y After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary, and wipe up spilled fuel. Oil Filter Oil Drain Hose And Valve Oil Fill Cap Fuel Line Primary Fuel Filter (Fuel/...

  • Page 34: Overload Protection

    7-7. Overload Protection OM-491 Page 30 Y Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. Fuse F1 Fuse F2 F1 and F2 protect the stator exciter winding from overload.

  • Page 35: Diagnosing Causes Of Engine Fault Shutdowns

    7-8. Diagnosing Causes Of Engine Fault Shutdowns Pre-Start Diagnostic Checks Turn Engine Control Switch To Run/Idle Position While Pressing Magnetic Shut- down Switch. Diagnostic Checks While Running Start Engine (With No Load Applied). Normal Condition: Oil Pressure And Battery Charging Lights On; Fuel And Temperature Lights Off.

  • Page 36: Troubleshooting

    7-9. Troubleshooting A. Welding Trouble No weld output; auxiliary power output Check position of Ampere Range switch. okay. Check position of optional polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote control to Remote Amperage Adjust receptacle RC13 (see Sections 4-10 and 5-1).
  • Page 37 B. Auxiliary Power Trouble No auxiliary power output; weld output Reset receptacle circuit breakers. okay. No auxiliary power or weld output. Disconnect equipment from auxiliary power receptacles during start-up. Check fuses F1 and F2, and replace if open (see Section 7-7). Have Factory Authorized Service Agent check integrated rectifier SR1, capacitor C9, and the rotor.
  • Page 38 Trouble See engine manual. Battery discharges between uses. Turn Engine Control switch off when unit is not running. Clean top of battery with baking soda and water solution; rinse with clear water. Recharge or replace battery if necessary. Periodically recharge battery (approximately every 3 months). Engine idles, but does not come up to Have Factory Authorized Service Agent check Engine Control switch S1.
  • Page 39 Notes OM-491 Page 35...

  • Page 40: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram For Welding Generator OM-491 Page 36...
  • Page 41 191 550-C OM-491 Page 37...

  • Page 42: Section 9 − Run-In Procedure

    SECTION 9 − RUN-IN PROCEDURE 9-1. Wetstacking OM-491 Page 38 Welding Generator Run diesel engines near rated out- put during run-in period to properly seat piston rings and prevent wets- tacking. See nameplate or rating label to find rated output. Do not idle engine longer than necessary.

  • Page 43: Run-In Procedure Using Load Bank

    9-2. Run-In Procedure Using Load Bank Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. 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.

  • Page 44: Run-In Procedure Using Resistance Grid

    9-3. Run-In Procedure Using Resistance Grid OM-491 Page 40 Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Resistance Grid Use grid sized for generator rated output.

  • Page 45: Section 10 − Auxiliary Power Guidelines

    SECTION 10 − AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment 10-2. Grounding Generator To Truck Or Trailer Frame Be sure equipment has this symbol and/or wording. GND/PE Electrically bond generator frame to vehicle frame by metal-to-metal contact. Auxiliary Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double...

  • Page 46: Grounding When Supplying Building Systems

    10-3. Grounding When Supplying Building Systems 10-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
  • Page 47 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 10-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 48 10-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
  • Page 49 10-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
  • Page 50 10-10. Typical Connections To Supply Standby Power Customer-supplied equipment is required if generator is to supply standby power during emergencies or power outages. 120/240 Volt 60 Hz Three-Wire Service Load 120/240 Volt Single-Phase Three-Wire Generator Output Connection OM-491 Page 46 240 V 120 V 120 V...
  • Page 51 10-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 52: Section 11 − Parts List

    SECTION 11 − PARTS LIST Hardware is common and not available unless listed. 103−(Fig. 11-5) 109−(Fig. 11-3) OM-491 Page 48 15 16 Figure 11-1. Main Assembly...
  • Page 53 38 39 53−(Fig. 11-4) 93−(Fig. 11-2) 56 57 802 265 OM-491 Page 49...
  • Page 54 Item Dia. Part Mkgs....189 824 ....087 341 .
  • Page 55 Item Dia. Part Mkgs....189 245 ....124 253 .
  • Page 56 Item Dia. Part Mkgs..CR1, CR2 090 104 ....190 252 ..
  • Page 57 Hardware is common and not available unless listed. Item Dia. Part Mkgs..F1, F2 *085 874 ....046 432 .
  • Page 58 Hardware is common and not available unless listed. OM-491 Page 54 Figure 11-3. Panel, Front w/Components 802 266...
  • Page 59 Item Dia. Part Mkgs..........191 359 .
  • Page 60 802 267 Figure 11-4. Generator OM-491 Page 56...
  • Page 61 Item Dia. Part Mkgs....127 595 ....183 387 .
  • Page 62 Hardware is common and not available unless listed. Item Dia. Part Mkgs....188 137 ....188 517 .
  • Page 63 Miller distributor. LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 64: Options And Accessories

    Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 1999 Miller Electric Mfg. Co. 9/98 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA &...

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Big blue 602p

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