Gebruiksaanwijzing /service van het product Big Blue 502P van de fabrikant Miller Electric
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Big Blue 402P , 502P , 602P OM -491 190 355AP October 2003 Visit our website at www.Miller Welds .com Processes Descrip tio n Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMAW ) W elding Engi.
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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 8 − OPERA TING AUXILIARY EQUIPMENT 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. 120 V olt And 240 V olt Receptacles 31 . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-491 Page 1 Return T o T able Of Contents SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_8/03 W arning: Protect yourself and others from injury — read and follow these precautions.
OM-491 Page 2 Return T o T able Of Contents W elding 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.
OM-491 Page 3 Return T o T able Of Contents STEAM AN D H O T C OOLANT can burn. If possible, check coolant level when engine is cold to avoid scalding. Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).
OM-491 Page 4 Return T o T able Of Contents READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als.
OM-491 Page 5 Revenez à la table des matières SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 8/03 A vertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.
OM-491 Page 6 Revenez à la table des matières LES ACCUMULA TIONS DE GAZ ris- quent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz protecteur en cas de non utilisation. V eiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué.
OM-491 Page 7 Revenez à la table des matières L ’EXPLOSION DE LA BA TTERIE peut RENDRE A VEUGLE. T oujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.
OM-491 Page 8 Revenez à la table des matières LE SURCHAUFFEMENT peut endom- mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur .
OM-491 Page 9 Return T o T able Of Contents SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Starting Aid Battery (Engine) Engine Oil.
OM-491 Page 10 Return T o T able Of Contents 4-1. W eld, Power , And Engine Specifications W elding Mode W eld Output Range Rated W elding Output Maximum Open- Circuit V oltage Generator Power Rating .
OM-491 Page 1 1 Return T o T able Of Contents 4-3. V olt-Ampere Curves For CC Models 203 412 The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown.
OM-491 Page 12 Return T o T able Of Contents 4-4. V olt-Ampere Curves For CC/CV Models 203 414 / 203 415 / 203 413 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown.
OM-491 Page 13 Return T o T able Of Contents 4-5. Fuel Consumption The curve shows typical fuel use under weld or power loads. 193 093 0 50 100 150 200 250 300 350 400 450 500 DC WELD AMPERES A T 100% DUTY CYCLE 1800 RPM 0 IDLE Continuous W elding 4-6.
OM-491 Page 14 Return T o T able Of Contents 4-7. AC Generator Power Curve 193 018 Th e ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 0 50 100 150 200 250 300 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE AC VOL TS 0 25 50 75 100 150 125 0 1 0 2 03 0 4 05 0 6 0 AC AMPERES IN 120V MODE 4-8.
OM-491 Page 15 Return T o T able Of Contents SECTION 5 − INST ALLA TION install3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274 Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.
OM-491 Page 16 Return T o T able Of Contents 5-2. Mounting Welding Generator T ools Nee d e d : 9/16 in 2 2 3 4 W elding Unit In Place Bolting Unit In Place Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.
OM-491 Page 17 Return T o T able Of Contents 5-3. Using Lifting Eye Ref. 802 169-F 1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps in place.
OM-491 Page 18 Return T o T able Of Contents 5-5. Activating The Dry Charge Battery (If Applicable) Remove b attery from unit. 1 Eye Protection − Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 W ell Fill each cell with electrolyte to bottom of well (maximum).
OM-491 Page 19 Return T o T able Of Contents 5-6. Connecting The Battery 1/2 i n − + Connect Negative (−) Cable Last. T ools Needed: 802 168-E / Ref.
OM-491 Page 20 Return T o T able Of Contents Ref. 802 168-E 5-7. Engine Prestart Checks Check all engine fluids daily . Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. The Automatic shutdown system stops en- gine if fuel level or oil pressure is too low , or coolant temperature is too high.
OM-491 Page 21 Return T o T able Of Contents 5-8. Connecting T o W eld Output T erminals Ref. 802 169-E Stop engine. 1 Positive (+) Weld Output T erminal 2 Negative (−) Weld Output T erminal For.
OM-491 Page 22 Return T o T able Of Contents 5-10. Connecting T o Remote Amperage Adjust Receptacle RC13 On CC Models Ref. 154 862-A / 048 720-K / 802 160-E 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 6-3).
OM-491 Page 23 Return T o T able Of Contents SECTION 6 − OPERA TING WELDING GENERA TOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2 ) 17 202 705 / 802 169-F 15 16 2 1 3 13 .
OM-491 Page 24 Return T o T able Of Contents 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1 ) Engine Starting Controls 1 Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure o r fuel level is too low or coolant tem- perature is too high.
OM-491 Page 25 Return T o T able Of Contents 6-3. Remote Amperage Control On CC Models (Optional) 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-10 ).
OM-491 Page 26 Return T o T able Of Contents Notes.
OM-491 Page 27 Return T o T able Of Contents SECTION 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2 ) 202 706 / 802 31 1-D 6 5 47 13 1.
OM-491 Page 28 Return T o T able Of Contents 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1 ) Engine Starting Controls 1 Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or engine temperature is too high.
OM-491 Page 29 Return T o T able Of Contents 7-3. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch W eld output terminals are ener- gized when Process/Contactor switch is in an Electrode Hot position and the engine is run- ning.
OM-491 Page 30 Return T o T able Of Contents 7-4. Remote V oltage/Amperage Control On CC/CV Models (Optional) 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-1 1).
OM-491 Page 31 Return T o T able Of Contents SECTION 8 − OPERA TING AUXILIAR Y EQUIPMENT 8-1. 120 V olt And 240 V olt Receptacles 191 624-A 2 1 3 4 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 30 A AC T wistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.
OM-491 Page 32 Return T o T able Of Contents 8-2. Connecting T o Optional Three-Phase Generator (CC/CV Models Only) Ref. 197 399 / 802 332-E Place Process/Contactor switch in Electrode Hot - Stick position when using three−phase genera- tor (see Section 7-3).
OM-491 Page 33 Return T o T able Of Contents 8-3. Optional Generator Power Receptacles 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 16 A AC European Receptacle RC1 3 240 V 15 A AC Australian Receptacle RC1 4 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.
OM-491 Page 34 Return T o T able Of Contents SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Routine Maintenance Follow the storage procedure in the engine owner ’s manual if the unit will not be used for an extended period. Note Recycle engine fluids.
OM-491 Page 35 Return T o T able Of Contents Every 400 h Change Oil. See Section 9-6. Change Oil Filter . S e e Section 9-6. Check Radiator Fluid Level. See Section 5-7. Change Fuel Filters. See Section 9-6. Check V alve Clearance.* Every 500 h Repair Or Replace Damaged Cables.
OM-491 Page 36 Return T o T able Of Contents 9-2. Maintenance Label.
OM-491 Page 37 Return T o T able Of Contents 9-3. Servicing Air Cleaner aircleaner1 9/00 − ST -153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 202 705 Stop engine. Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty .
OM-491 Page 38 Return T o T able Of Contents 9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler 802 160-E / Ref. 202 705 Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole.
OM-491 Page 39 Return T o T able Of Contents 9-5. Adjusting Engine Speed 802 168-C / 802 229-A / Ref. 202 705 Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer or frequen- cy meter .
OM-491 Page 40 Return T o T able Of Contents 9-6. Servicing Fuel And Lubrication Systems 802 170-D / Ref. 802 168-B / Ref. 801 434 Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary , and wipe up spilled fuel.
OM-491 Page 41 Return T o T able Of Contents 9-7. Overload Protection 802 170-E 21 9 8 7 4 Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exciter winding from overload.
OM-491 Page 42 Return T o T able Of Contents 9-8. Diagnosing Causes Of Engine Fault Shutdowns Ref. 202 705 Use the front panel engine lights to help determine the cause of an au- tomatic engine shutdown. Correct the cause of the shut- down before operating the welding generator .
OM-491 Page 43 Return T o T able Of Contents 9-9. T roubleshooting A. Welding − CC Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Check position of Ampere Range switch. Check position of optional polarity switch.
OM-491 Page 44 Return T o T able Of Contents B. Welding − CC/CV Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote p osition and connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-1 1 and 7-1).
OM-491 Page 45 Return T o T able Of Contents T rouble Remedy Min or max CV weld output only . Check position of V oltage/Amperage Adjust control and V oltage/Amperage Adjust switch. Repair or replace remote control device. Have Factory Authorized Service Agent check field current regulator board PC1.
OM-491 Page 46 Return T o T able Of Contents T rouble Remedy Engine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine. Check fuel level. Reset circuit breaker CB13 (see Section 9-7). Have Factory Authorized Service Agent check engine wir- ing harness and components.
OM-491 Page 47 Return T o T able Of Contents Notes.
OM-491 Page 48 Return T o T able Of Contents SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator.
OM-491 Page 49 Return T o T able Of Contents 215 304-A.
OM-491 Page 50 Return T o T able Of Contents Figure 10-2. Circuit Diagram For CC/CV Welding Generator.
OM-491 Page 51 Return T o T able Of Contents 215 305-A.
OM-491 Page 52 Return T o T able Of Contents SECTION 1 1 − RUN-IN PROCEDURE run_in1 8/0 1 1 1-1. Wetstacking Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur .
OM-491 Page 53 Return T o T able Of Contents 1 1-2. Run-In Procedure Using Load Bank S-0683 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid.
OM-491 Page 54 Return T o T able Of Contents 1 1-3. Run-In Procedure Using Resistance Grid S-0684 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid.
OM-491 Page 55 Return T o T able Of Contents SECTION 12 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. NOTE 12-1. Selecting Equipment gen_pwr 1 1/02 − Ref.
OM-491 Page 56 Return T o T able Of Contents 12-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
OM-491 Page 57 Return T o T able Of Contents 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 5.
OM-491 Page 58 Return T o T able Of Contents 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2.
OM-491 Page 59 Return T o T able Of Contents 12-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage.
OM-491 Page 60 Return T o T able Of Contents 12-10. T ypical Connections T o Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practic- es. Properly install and ground this equipment according to its Owner ’ s Manual and national, state, and local codes.
OM-491 Page 61 Return T o T able Of Contents 12-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
OM-491 Page 62 Return T o T able Of Contents SECTION 13 − P ARTS LIST Hardware is common and not available unless listed. 3 2 1 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 .
OM-491 Page 63 Return T o T able Of Contents 802 265-G 11 4 44 11 5 Big Blue 502, 602 Only 35 36 37 38 39 40 41 42 43 44 45 46 (FIG 13-6) 47 48 49 50 51 52 53 54 55 54 54 56 57 58 59 60 61 62 63 64 65.
OM-491 Page 64 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly Quanti ty 1 189 824 P ANEL, gen LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-491 Page 65 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quanti ty 44 010 875 CLAMP , muf fler 2.000 dia 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-491 Page 66 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quanti ty 79 191 610 FITTING, hose stl elbow .500tbg x 3/4-16 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-491 Page 67 Return T o T able Of Contents 802 551-E 2 1 11 8 6 3 7 14 20 13 16 12 5 22 15 10 9 18 17 4 21 19 Figure 13-2. Control Box Assembly − CC Models Description Part No. Dia. Mkgs. Item No. Figure 13-2. Control Box Assembly − CC Models (Figure 13-1 Item 104) Quanti ty 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 .
OM-491 Page 68 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-2. Control Box Assembly − CC Models (Continued) Quanti ty 190 260 HARNESS, unit weld control (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . .
OM-491 Page 69 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 104) Quanti ty 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 . . . . . . . . . . . . . . .
OM-491 Page 70 Return T o T able Of Contents Hardware is common and not available unless listed. 802 266-D 1 3 4 5 12 15 18 23 24 26 29 32 35 36 37 38 44 45 46 17 25 30 31 16 20 2 22 27 28 13 19 14 6 7 8 9 10 21 34 33 11 39 40 41 42 43 Figure 13-4.
OM-491 Page 71 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-4. Panel, Front w/Components − CC Models (Continued) Quanti ty 8 S5 01 1 609 SWITCH, tgl SPDT 15A 125V AC on-none-on spd term chr (included in . . . . . .
OM-491 Page 72 Return T o T able Of Contents Hardware is common and not available unless listed. 802 332-F 1 2 3 4 5 6 7 9 48 50 51 52 53 59 60 61 62 13 18 19 20 21 22 23 24 25 26 27 30 28 29 15 16 34 33 32 17 35 42 43 41 40 39 38 37 36 44 47 14 10 49 11 8 31 45 46 12 54 55 56 57 58 63 Figure 13-5.
OM-491 Page 73 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued) Quanti ty 5 R1 193 1 18 POT , cp flat 1t 2w 1k ohm linear 1 . . . . . . . . . . . . . . . . . . .
OM-491 Page 74 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued) Quanti ty 52 FUEL 191 242 GAUGE, fuel elec switch 1 . . . . . . . . . . . . . . . . . . . . . . .
OM-491 Page 75 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-6 . Generator (Figure 13-1 Item 46) Quanti ty 1 132 053 SCREW, 375-16 x 1.50hexhd pln gr 5pld 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-491 Page 76 Return T o T able Of Contents Hardware is common and not available unless listed. 802 279-A 1 2 3 4 6 5 7 8 9 Figure 13-7. Main Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 13-7. Main Rectifier Assembly (Figure 13-1 Item 1 1 1) Quanti ty SR3 201 747 RECTIFIER (consisting of) 1 .
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 8/03 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor .
PRINTED IN USA 2003 Miller Electric Mfg. Co. 1/03 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 West Spencer Street Applet on, WI 54914 US A International He adquarters− US.
Een belangrijk punt na aankoop van elk apparaat Miller Electric Big Blue 502P (of zelfs voordat je het koopt) is om de handleiding te lezen. Dit moeten wij doen vanwege een paar simpele redenen:
Als u nog geen Miller Electric Big Blue 502P heb gekocht dan nu is een goed moment om kennis te maken met de basisgegevens van het product. Eerst kijk dan naar de eerste pagina\'s van de handleiding, die je hierboven vindt. Je moet daar de belangrijkste technische gegevens Miller Electric Big Blue 502P vinden. Op dit manier kan je controleren of het apparaat aan jouw behoeften voldoet. Op de volgende pagina's van de handleiding Miller Electric Big Blue 502P leer je over alle kenmerken van het product en krijg je informatie over de werking. De informatie die je over Miller Electric Big Blue 502P krijgt, zal je zeker helpen om een besluit over de aankoop te nemen.
In een situatie waarin je al een beziter van Miller Electric Big Blue 502P bent, maar toch heb je de instructies niet gelezen, moet je het doen voor de hierboven beschreven redenen. Je zult dan weten of je goed de alle beschikbare functies heb gebruikt, en of je fouten heb gemaakt die het leven van de Miller Electric Big Blue 502P kunnen verkorten.
Maar de belangrijkste taak van de handleiding is om de gebruiker bij het oplossen van problemen te helpen met Miller Electric Big Blue 502P . Bijna altijd, zal je daar het vinden Troubleshooting met de meest voorkomende storingen en defecten #MANUAl# samen met de instructies over hun opplosinge. Zelfs als je zelf niet kan om het probleem op te lossen, zal de instructie je de weg wijzen naar verdere andere procedure, bijv. door contact met de klantenservice of het dichtstbijzijnde servicecentrum.
