Miller big blue 700 duo pro Owner'S Manual Download Page 1

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Processes

OM-252 624D

2012

−

Big Blue 700 Duo Pro

Big Blue 700X Duo Pro

Processes

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

Engine Driven Welding Generator

Visit our website at

www.MillerWelds.com

Air Carbon Arc (CAC-A)

Cutting and Gouging

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

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File: Engine Drive

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Summary of Contents for big blue 700 duo pro

Page 1: ...ig Blue 700X Duo Pro Processes Description TIG GTAW Welding Stick SMAW Welding Engine Driven Welding Generator Visit our website at www MillerWelds com Air Carbon Arc CAC A Cutting and Gouging MIG GMA...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...ere Curves 20 4 5 Volt Ampere Curves For Paralleled Output 21 4 6 Fuel Consumption 22 4 7 Duty Cycle And Overheating 22 4 8 AC Generator Power Curves 23 SECTION 5 INSTALLATION 25 5 1 Serial Number And...

Page 4: ...TION 8 MAINTENANCE TROUBLESHOOTING 51 8 1 Maintenance Label 51 8 2 Routine Maintenance 52 8 3 Checking Generator Brushes 53 8 4 Servicing Air Cleaner 54 8 5 Adjusting Engine Speed 55 8 6 Servicing Fue...

Page 5: ...gh risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC m...

Page 6: ...ks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on con...

Page 7: ...e hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can burn If possible check coolant level when engine is cold to avoid scaldi...

Page 8: ...PARTS can burn Do not touch hot compressor or air system parts Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insu lated welding gloves and cl...

Page 9: ...Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use...

Page 10: ...ebsite www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY...

Page 11: ...appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures...

Page 12: ...n casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dan...

Page 13: ...er des tincelles avec les outils en travaillant sur la batterie Ne pas utiliser l appareil de soudage pour charger des batteries ou faire d marrer des v hicules l aide de c bles de d marrage sauf si l...

Page 14: ...imentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit d air ne peut tre mis sous pression par inadvertance Ne pas intervenir sur le circuit d air com...

Page 15: ...uer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et...

Page 16: ...al R duire le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s tablir la...

Page 17: ...ian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And...

Page 18: ...ric shock by insulating yourself from work and ground Safe3 2012 05 Keep your head out of the fumes Safe6 2012 05 Use forced ventilation or local exhaust to remove the fumes Safe8 2012 05 Use ventilat...

Page 19: ...ollar Use welding helmet with correct shade of filter Wear complete body protection Safe38 2012 05 Kasjf laksf lkasdf l aksdf lkasd flksadflkasd lk Kasjf laksf lkasdf l aksdf lkasd flksadflkasd lk Kas...

Page 20: ...ation keep welding load above 200 amperes Do not weld below 200 amperes of output 50 h std Safe55 2012 05 After the first 50 hours of operation change the engine oil and filter Notes Work like a Pro P...

Page 21: ...Engine Air Temperature Or Engine Temperature Output Alternating Current Stick SMAW Welding Constant Current CC FCAW Welding TIG GTAW Welding Time h Hours s Seconds 1 Single Phase 3 Three Phase Read Op...

Page 22: ...12 000 Watts Con tinuous 75dB 100 Lwa Separate dual out puts 20 400A Each Side 300A at 32V 100 Duty Cycle Each Side 400A at 36V 40 Duty Cycle One Side only CV DC MIG FCAW Paralleled combined 14 40VDC...

Page 23: ...of muffler Width 28 1 2 in 724 mm mtg brackets turned in 30 3 4 in 781 mm mtg brackets turned out Depth 65 1 8 in 1654 mm A 65 1 8 in 1654 mm B 56 in 1422 mm C 46 1 2 in 1181 D 9 5 8 in 244 mm E 27 1...

Page 24: ...perage output capabilities of the welding generator Curves of all other settings fall between the curves shown A Stick Mode B TIG Mode C MIG Mode 0 20 40 60 80 100 0 100 200 300 400 DC VOLTS DC AMPERE...

Page 25: ...elding generator Curves of all other settings fall between the curves shown A Stick Mode B TIG Mode C MIG Mode 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 DC VOLTS DC AMPERES PARALLELEDOUTPUT...

Page 26: ...ngle Arc Dual Arcs 95 1 90 2 84 3 79 4 73 5 69 6 62 7 57 Liters Hr 8 52 9 46 Paralleled Arc 10 41 4 7 Duty Cycle And Overheating 253 022 A 1 100 Duty Cycle Duty Cycle is percentage of 10 min utes that...

Page 27: ...he AC power curve shows the generator power in amperes A Single Phase 4 kW B Three Phase Optional 380 VAC 20 kW 1 8 0 2 0 0 2 2 0 2 4 0 2 6 0 2 8 0 0 1 0 2 0 3 0 4 0 AC V O LT S AC AMPERES 3 2 0 3 4 0...

Page 28: ...ingle Phase 12 kW D Three Phase North American 20 kW 4 7 AC Generator Power Curves Continued 70 60 50 40 30 20 10 0 180 200 220 240 260 280 AC VOLTS AC AMPERES AC VOLTS AC AMPERES 140 280 135 270 130...

Page 29: ...not move or operate unit where it could tip Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes NOTICE Do not install unit w...

Page 30: ...s Supports 2 Mounting Brackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 8 16 x 1...

Page 31: ...does not have GFCI receptacles use GFCI protected extension cord Do not use GFCI receptacles to power life support equipment 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Suppli...

Page 32: ...907 520 4 Connect negative battery cable last Close cover after connecting bat tery Notes BUTT BUTT BUTT BUTT T JOINT T JOINT T JOINT T JOINT FILLET GROOVE FLAT VERTICAL HORIZONTAL OVERHEAD WELD POSI...

Page 33: ...shipped with enough fuel to pre vent air from entering fuel system Add fresh diesel fuel before starting see engine main tenance label for fuel specifications Leave filler neck empty to allow room fo...

Page 34: ...ble terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean 1 Correct Weld Cable Connection 2 Incorrect Weld Cable Connection 3 Weld Output Terminal 4 S...

Page 35: ...G welding Direct Current Elec trode Positive DCEP connect work cables to Negative terminals and elec trode holder cables to Positive termi nals For Stick TIG Direct Current Electrode Negative DCEN con...

Page 36: ...TICE Do not exceed machine duty cycle Use Dual Operator mode for CC and CV welding see Section 6 2 1 Electrode Holder Cables 2 Work Jumper Cable 3 Common Work Cable For Stick TIG welding Direct Curren...

Page 37: ...Feeder Cables 2 Work Cables For MIG and FCAW welding Direct Current Electrode Positive DCEP connect work cables to Negative terminals and wire feeder cables to Positive terminals For MIG and FCAW Dire...

Page 38: ...must be able to carry combined weld output of both CC weld output ter minals see Section 5 16 for proper cable size Use Dual Operator mode for CC and CV welding see Section 6 2 1 Wire Feeder Cables 2...

Page 39: ...Current Electrode Negative DCEN connect work cable to Positive terminal and electrode holder cable to Negative terminal Be sure Process Selector switches are set correctly See Section 6 3 For MIG and...

Page 40: ...Section 6 2 1 Electrode Holder Cable 2 Wire Feeder Cable 3 Work Jumper Cable 4 Common Work Cable For Direct Current Electrode Positive DCEP connect common work cable and work jumper cable to Welder B...

Page 41: ...see Section 6 2 See Section 5 16 for proper cable size 1 Electrode Holder Cable 2 Work Cable For Stick TIG welding Direct Current Elec trode Positive DCEP connect work cable to Negative terminal and e...

Page 42: ...60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 1...

Page 43: ...upplementary protector B Contact closure to A completes 24 volt AC contactor control circuit REMOTE OUTPUT CONTROL C Output to remote control 10 volts DC in MIG mode 0 to 10 volts DC in Stick or TIG m...

Page 44: ...OM 252 624 Page 40 SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls See Section 6 2 251 246 A 251 340 A 1 2 5 4 6 7 8 9 3 10 11 12 13...

Page 45: ...until desired amperage is displayed on Ammeter When welding is finished ammeter displays weld amperage and then defaults to preset amperage 8 DC Voltmeter Voltmeter displays preset voltage MIG weld in...

Page 46: ...c Welding uses a voltage sensing VS feeder that does not re quire a control cable back to the welding generator Electrode Hot Stick Stick welding with or without a remote amperage control Strike an ar...

Page 47: ...uctance deter mines the wetness of the weld puddle Increasing Arc Control set ting decreases inductance thereby increasing puddle fluidity wet ness Decreasing Arc Control set ting increases inductance...

Page 48: ...ntactor switch Turn gas on 1 Touch or scratch 2 Lift at any angle Touch tungsten electrode to workpiece at weld start point Slowly lift electrode Arc is started when electrode is lifted Maintain shiel...

Page 49: ...Control On Ad just Optional Remote Control to 100 Set V A Control To Desired Maximum Weld Output Using Weld Meters Set TIG or STICK Process In Example Min 20 A DC Max 205 A DC Max 205 A DC Min 20 A D...

Page 50: ...eceptacle Heater rated at 300 watts Do not run engine while oil pan heater is on NOTICE In extremely cold weath er heater should be connected to power source when engine oil is warm to eliminate possi...

Page 51: ...OM 252 624 Page 47 6 8 Fuel Hour Gauge Descriptions...

Page 52: ...ress but ton to reset CB8 protects GFCI2 from overload If CB8 opens GFCI2 does not work Press but ton to reset If a supplementary protector contin ues to open contact Factory Autho rized Service Agent...

Page 53: ...supplies 50 60 Hz three phase power 8 Supplementary Protector CB5 CB5 protects the auxiliary power winding from over current If CB5 opens the 110 volt receptacles and 220 volt receptacles do not work...

Page 54: ...cording to the following procedures Resetting Testing GFCI Receptacle Test GFCI monthly See Testing GFCI Receptacle Do not test or reset GFCI recept acles at idle speed low voltage or the GFCI will be...

Page 55: ...s to handle your differ ent needs The DEUTZ Service Desk enhances this sup port and can be contacted by completing and submittingthe Service Support Form Customer in the US and CANADA can also contact...

Page 56: ...ry 50 Hours Weld Terminals Every 100 Hours Section 8 4 Battery Terminals Air Cleaner Hoses Air Cleaner Element Every 250 Hours 1 2 in 13 mm Engine Manual Unreadable Labels Fan Belt Tension Cooling Sys...

Page 57: ...0 823 Stop engine and let cool 1 Generator Brush Mark and disconnect leads at brush hold er cap Remove brushes Replace brushes if damaged or if brush material is at or near minimum length 1 Damaged Br...

Page 58: ...the safety element after servi cing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary eleme...

Page 59: ...or switch to Stick Electrode Hot position 1 Throttle Rod 2 Locknut 3 Throttle Stop Screw 4 Throttle Lever Loosen locknuts Place engine control switch in Run Idle position Turn throttle rod until engin...

Page 60: ...flows To replace primary fuel filter Turn filter counterclockwise Remove filter Apply thin coat of fuel to gasket on new filter Fill filter with fuel Install filter and turn clock wise Bleed air from...

Page 61: ...Not Shown CB9 and CB29 protect the 24 volt AC out put to remote receptacles and 24 volt out put to field current regulator board PC If CB opens weld output and 24 volt output to remote receptacle stop...

Page 62: ...e Keep engine ac cess door closed when running to maintain proper cooling air flow past the heat sinks Allow unit to cool before restarting If prob lem continues have Factory Authorized Service Agent...

Page 63: ...e Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Erratic weld output Check and tighten connections inside and outside unit Be sure connection to work piece...

Page 64: ...es and slip rings and field excitation circuit High output at generator power AC re ceptacles Check engine speed and adjust if necessary Have Factory Authorized Service Agent adjust generator power fi...

Page 65: ...condition Store battery in warm area off cold surface Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel information Use correct grade oil f...

Page 66: ...OM 252 624 Page 62 SECTION 9 ELECTRICAL DIAGRAMS Figure 9 1 Circuit Diagram For Export Welding Generator...

Page 67: ...OM 252 624 Page 63 250 340 E...

Page 68: ...OM 252 624 Page 64 Figure 9 2 Circuit Diagram For North American Welding Generator...

Page 69: ...OM 252 624 Page 65 249 603 D...

Page 70: ...ton rings seat faster if engine runs at weld power rpm and the welding generator is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs...

Page 71: ...nerator Side A weld output terminals using proper size weld cables with cor rect connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust gen...

Page 72: ...con nectors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and...

Page 73: ...ealth Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Gen erators 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable fr...

Page 74: ...e load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when...

Page 75: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100...

Page 76: ...HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1...

Page 77: ...must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Vol...

Page 78: ...d back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch...

Page 79: ...0 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 Use GFCI protection when operating auxiliary...

Page 80: ...24 Page 76 SECTION 12 PARTS LIST Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 907 520 5 30 Figure 12 1 Main Assembly...

Page 81: ...4 206352 Brace Front To Center Upright 2 15 252809 Firewall Top 1 16 218086 Bracket Holddown Fuel Tank 1 17 196220 Bracket Holddown Fuel Tank Rear 1 18 192362 Bracket Mtg Nyl 1 2 Conduit 1 19 173352 E...

Page 82: ...7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 7...

Page 83: ...Gen Nprn 875 Id X 2 500 Od X 2 000 4 21 135205 Nut 625 11 94hex 76h Stl Pld Elastic Stop Nut 4 22 071730 Tubing Stl 875 Od X 12ga Wall X 2 500 4 23 191812 Bracket Mtg Engine Rh 1 24 199507 Hose Oil D...

Page 84: ...406rng 1 62 108081 Terminal Protector Battery Post Mtg 2 63 190206 Cable Bat Neg 42 In Lg No 2 Awg W Clamp And 375rng 1 64 191446 Extrusion Rubber W Adhesive 1 000 X 1 000 D Order By Ft 6ft 65 218087...

Page 85: ...12 Amp 1 8 CB10 190374 Circuit Breaker Auto Reset 12vdc 40a 1 9 201079 Cover Control Box 1 10 PC6 251949 Circuit Card Assy Field Current Regulator 1 11 CR8 197325 Relay Encl 12vdc Spst 70a 4 Pin Flang...

Page 86: ...Card Assy Display W Program 2 10 248914 Enclosure Circuit Card Assy 2 11 134201 Stand off Support Pc Card 312 375w Post Lock 43 8 12 PC5 PC25 242263 Circuit Card Assy Connector Receptacle 2 13 CB9 CB2...

Page 87: ...2 010647 Pin Spring 1 3 111785 Handle Switch 1 4 Nameplate Order By Model Serial No 1 5 248895 Panel Mtg Terminal Power Output 1 6 241432 Terminal Pwr Output Red 2 7 241433 Terminal Pwr Output Blk 2...

Page 88: ...3 Supplementary Protector Man Reset 2p 20a 250vac 1 7 248894 Panel Aux Power 1 8 025248 Stand off Insul 250 20 X 1 250 Lg X 437 Thd 1 9 GFCI1 2 246865 RCPT str dx grd 2P3W 20A 125V 5 20r GFI 2 10 CB1...

Page 89: ...5v 5 20r Gfi 2 6 CB1 214926 Supplementary Protector Man Reset 3p 50a 250vac 1 7 ELCB1 222991 Circuit Breaker Elcb 16a 220v 0 030a Trip 1 8 CB5 117501 Supplementary Protector Man Reset 1p 40a 250vac 1...

Page 90: ...t Breaker 1 Pole 1 7 CB1 254884 Supplementary Protector Man Reset 3p 30a 480vac 1 8 ELCB1 222991 Circuit Breaker Elcb 16a 220v 0 030a Trip 1 9 CB5 117501 Supplementary Protector Man Reset 1p 40a 250va...

Page 91: ...Mtg Rectifier 1 7 SR6 SR26 248933 Rectifier Si 3ph 300 Amp 600 Piv 2 8 HD1 HD21 168829 Transducer Current 1000a Module Max Open Loop 2 9 239547 Washer Flat Nylon 516 Id X 1 250 Od X 062 Thk 4 10 C3 C2...

Page 92: ...e Export Models 1 7 225120 Label Warning Moving Parts Can Cause Injury 2 8 190197 Guard Generator Wire Mesh 1 9 172674 Spring Ext 240 Od X 041 Wire X 3 500pld 2 10 039207 Baffle Air 1 11 ROTOR 251855...

Page 93: ...8 602211 Washer Lock 318idx0 586odx 078t Stl Pld Split 312 4 29 604950 Screw 312 18x2 00 Hex Hd pln Gr5 Pld 4 602211 Washer Lock 318 Id X 0 586 2 604534 Screw 312 18x1 25 Hex Hd pln Gr5 Pld 2 602242 W...

Page 94: ...9 14 214934 Seal Plug Univ 039 6 249646 Harness Weld Control Includes 1 PLG6 PLG26 193184 Conn Rect Cinch 30 Pin 2 PLG7 11 27 211 193183 Conn Rect Cinch 18 Pin 4 PLG5 10 20 25 210 220113751 Conn Rect...

Page 95: ...ontrols and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils...

Page 96: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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