Miller Big Blue 800 DUO PRO Owner'S Manual Download Page 3

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TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

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1-1.

Symbol Usage

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1-2.

Arc Welding Hazards

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1-3.

Engine Hazards

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1-4.

Compressed Air Hazards

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1-5.

Additional Symbols For Installation, Operation, And Maintenance

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1-6.

California Proposition 65 Warnings

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1-7.

Principal Safety Standards

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1-8.

EMF Information

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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

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2-1.

Signification des symboles

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2-2.

Dangers relatifs au soudage à l’arc

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2-3.

Dangers existant en relation avec le moteur

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2-4.

Dangers liés à l’air comprimé

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2-5.

Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

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2-6.

Proposition californienne 65 Avertissements

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2-7.

Principales normes de sécurité

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2-8.

Informations relatives aux CEM

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SECTION 3 − DEFINITIONS

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3-1.

Additional Safety Symbols And Definitions

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3-2.

Miscellaneous Symbols And Definitions

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SECTION 4 − SPECIFICATIONS

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4-1.

Serial Number And Rating Label Locations

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4-2.

Weld, Power, And Engine Specifications

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4-3.

Dimensions, Weights, And Operating Angles

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4-4.

Environmental Specifications

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4-5.

Duty Cycle And Overheating

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4-6.

Fuel Consumption

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4-7.

Volt-Ampere Curves

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4-8.

AC Generator Power Curves

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SECTION 5 − INSTALLATION

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5-1.

Installing Welding Generator

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5-2.

Grounding Generator To Truck Or Trailer Frame

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5-3.

Installing Exhaust Pipe

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5-4.

Connecting The Battery

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5-5.

Engine Prestart Checks

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5-6.

Connecting To Weld Output Terminals

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5-7.

Making Dual Operator CC Weld Connections w/ Separate Work Cables

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5-8.

Making Dual Operator Mode CC Weld Connections w/ Common Work Cable

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5-9.

Making Dual Operator CV Weld Connections w/ Separate Work Cables

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5-10. Making Dual Operator CV Weld Connections w/ Common Work Cable

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5-11. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables

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5-12. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable

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5-13. Making Single Operator CC Weld Connections

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5-14. Weld Output Terminals And Selecting Cable Sizes*

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5-15. Connecting To Remote 14 Receptacle

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Summary of Contents for Big Blue 800 DUO PRO

Page 1: ...0 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 F...

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: ...l Number And Rating Label Locations 18 4 2 Weld Power And Engine Specifications 18 4 3 Dimensions Weights And Operating Angles 18 4 4 Environmental Specifications 18 4 5 Duty Cycle And Overheating 19...

Page 4: ...ormation Resetting And Testing 45 SECTION 8 MAINTENANCE 46 8 1 Routine Maintenance 46 8 2 Checking Generator Brushes 47 8 3 Battery Replacement 47 8 4 Servicing Air Cleaner 48 8 5 Engine Speed Adjustm...

Page 5: ...igh 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...

Page 6: ...ng sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor b...

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 insulated 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: ...r Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org St...

Page 11: ...areil 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 m t...

Page 12: ...es blessures ou m me la mort Fermer l alimentation du gaz comprim en cas de non utilisation Veiller toujours bien a rer les espaces confin s ou se servir d un respirateur d adduction d air homologu LE...

Page 13: ...e l ouverture de la vanne de la bouteille Ne pas se tenir devant ou derri re le r gulateur lors de l ouverture de la vanne Maintenir le chapeau de protection sur la soupape sauf en cas d utilisationou...

Page 14: ...appement 2 4 Dangers li s l air comprim Un QUIPEMENT PNEUMATIQUE risque de provoquer des blessures ou m me la mort Une installation ou une utilisation incorrecte de cet appareil pourrait conduire des...

Page 15: ...tion l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section N utiliser que les pi ces de rechange recommand es par le constructeur Effect...

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: ...n 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 Face Protec tion ANSI S...

Page 18: ...Protect yourself from electric 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...

Page 19: ...otection and button shirt collar 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 aksd...

Page 20: ...f operation change the engine oil and filter Never use generator inside a home or garage even if doors and win dows are open Safe87 2012 07 Only use generator outside and far away from windows doors a...

Page 21: ...ive Negative Output Welding Arc Off On Read Operator s Manual Remote 1 Single Phase 3 Three Phase Direct Current Alternating Current Stick SMAW Welding Lift Arc TIG MIG GMAW Welding TIG GTAW Welding F...

Page 22: ...Charged 65 7 HP Diesel Engine Tier 4 Final Compliant 25 gal 95 L CV DC 14 40 V 85 With Low OCV Voltage Reducing Device VRD switch enabled open circuit voltage is 13 to 15 volts DC until arc initiatio...

Page 23: ...dual operator mode or 800 am peres continuously in single operator mode NOTICE Exceeding duty cycle can damage unit and void warranty 1 4 6 Fuel Consumption The curve shows typical fuel use under wel...

Page 24: ...ies of the welding generator Curves of all other settings fall between the curves shown A Stick Mode B TIG Mode C MIG Mode 0 100 0 100 200 300 400 500 600 700 800 DC VOLTS DC AMPERES 0 20 40 60 80 100...

Page 25: ...ator power in amperes A Single Phase 4 kW 180 200 220 240 260 280 0 10 20 30 40 AC VOLTS AC AMPERES AC VOLTS AC AMPERES 140 280 135 270 130 260 125 250 120 240 115 230 110 220 105 210 100 200 95 190 9...

Page 26: ...h all DOT and other applicable codes Do not weld on base Welding on base can cause fuel tank fire or ex plosion Weld only on the four mounting brackets or bolt unit down NOTICE Do not mount unit by su...

Page 27: ...ng auxiliary equipment If unit 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 Pane...

Page 28: ...onnect battery negative cable last Reinstall battery ac cess panel Do not allow the battery cables to touch opposing terminals When connect ing the battery cables attach the positive cable to the posi...

Page 29: ...stacking or engine damage Follow run in procedure in engine manual If unburned fuel and oil collect in exhaust pipe see Section 13 Fuel NOTICE Do not use gasoline Gasoline will damage engine Add fres...

Page 30: ...ce anything between weld cable 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...

Page 31: ...r Cables 2 Work Cables For Stick TIG 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...

Page 32: ...tion 5 14 for proper cable size NOTICE 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 F...

Page 33: ...5 14 for proper cable size 1 Wire 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 Positi...

Page 34: ...ICE Do not exceed machine duty cycle For common work connection work cable must be able to carry combined weld output of both CC weld output ter minals see Section 5 14 for proper cable size Use Dual...

Page 35: ...al and elec trode holder cable to Positive terminal For Stick TIG Direct Current Electrode Negative DCEN connect work cable to Positive terminal and electrode holder cable to Negative terminal Be sure...

Page 36: ...Dual Operator mode for CC and CV welding see 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...

Page 37: ...e Operator mode see Section 6 2 See Section 5 14 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 Negativ...

Page 38: ...5 200 3 30 2 35 1 50 1 0 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...

Page 39: ...24 volts AC Protected by supplementary 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...

Page 40: ...Complete Parts List available at www MillerWelds com OM 262 752 Page 36 SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls See Section 6 2 262 528 907 587 1 1 2 5 4 6 7 8 9 3 10...

Page 41: ...actor switch information 8 24 Volts AC Overload Protection See Section 8 8 for overload protection in formation 9 Remote Control Receptacle Use receptacle to connect remote controls wire feeders and t...

Page 42: ...AW VS FCAW Flux Cored Arc 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 amper...

Page 43: ...itch Inductance 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 in...

Page 44: ...de touching the workpiece 1 ON OFF 6 7 Stick Start Procedure Scratch Start Technique With Stick selected start arc as follows 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like strikin...

Page 45: ...Lift Arc TIG at Process Contactor 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 electro...

Page 46: ...trol 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 DC Co...

Page 47: ...in a constant engine coolant temperature To turn on heater connect heater plug to 120 volts AC receptacle Do not run engine while en gine block heater is on NOTICE In extremely cold weath er heater sh...

Page 48: ...FCI1 does not work Press 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...

Page 49: ...and test GFCI receptacle according 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...

Page 50: ...Oil Oil Filter Fuel Filters Weld Cables Every 1000 Hours OR SLUDGE FUEL Section 8 2 8 7 and Engine Manual Slip Rings Brushes Inside Unit Valve Clearance Drain Sludge Every 2000 Hours NOTICE Use exten...

Page 51: ...minimum length 1 Damaged Brushes New Length 1 1 4 in 32 mm Minimum Length 5 8 in 16 mm Replace 8 3 Battery Replacement 255 858 Stop engine 1 Battery Locator Bracket Mounting Holes Access battery as sh...

Page 52: ...ement to pro vide additional engine protection Never clean a safety element Re place the safety element after servic ing the primary element three times 1 Engine Air Cleaner Clean or replace primary e...

Page 53: ...er TBN 9 mg KOH g Manufacturer Product Name SAE Class Weight Addinol Addinol Extra Truck MD 1049 LE 10W 40 Aral AG Aral Mega Turboral LA 10W 40 10W 40 BP Plc BP Vanellus Max Eco 10W 40 10W 40 Castrol...

Page 54: ...r Apply thin coat of fuel to gasket on new filter Fill filter with fuel Install filter and turn clock wise For primary fuel filter reconnect water sensor Bleed air from fuel system accord ing to engin...

Page 55: ...l circuit If CB3 opens weld output stops meters will be blank however generator power is still available CB4 protects the field flashing circuit If CB4 opens the generator may not excite at start up a...

Page 56: ...Keep engine access door closed when running to maintain proper cooling air flow past the heat sink Allow unit to cool before restarting If problem continues have Factory Authorized Ser vice Agent chec...

Page 57: ...r CB4 see Section 8 8 Check fuses F1 and F2 and replace if open see Section 8 8 Have Factory Authorized Service Agent check integrated rectifier SR2 capacitor C6 and the rotor Have Factory Authorized...

Page 58: ...see Section 8 8 Have Factory Authorized Service Agent check integrated rectifiers SR1 and SR2 capacitor C6 and the rotor Reset supplementary protector CB4 Have Factory Authorized Service Agent check i...

Page 59: ...5 Automatic shutdown system is inhibited for 30 seconds after start up See engine manual Engine slowly stopped and cannot be restarted Check fuel level Check engine air and fuel filters see Sections 8...

Page 60: ...OM 262 752 Page 56 SECTION 11 ELECTRICAL DIAGRAMS Figure 11 1 Circuit Diagram For Welding Generator Part 1...

Page 61: ...OM 262 752 Page 57 262 749 B...

Page 62: ...OM 262 752 Page 58 Figure 11 2 Circuit Diagram For Welding Generator Part 2...

Page 63: ...OM 262 752 Page 59 262 749 B...

Page 64: ...must occur If glow plugs are on automatically determined by ambient temperature also wait until the initial Wait to Start message on the display is cleared see Section 12 4 Function buttons are used...

Page 65: ...un or Run Idle position and glow plugs are functioning The operator needs to pause at either switch position while the engine controller goes through the preheat sequence Once this message clears the...

Page 66: ...y to appear 3 Engine Oil Pressure 4 Engine Coolant Temperature 5 Engine RPM 6 Compressor Air Pressure 7 Battery Voltage 8 Fuel Level 9 Engine Hourmeter 0 PSI 32 F 0 RPM 0 0 H 0 0 VDC 0 PSI 32 F 0 PSI...

Page 67: ...press the Previous function button To return to the 6 Up Display press the View function button Battery Potential 0V 0 3 6 9 12 15 18 Fuel Level 0 25 50 75 100 Machine Hours 0H 1 Coolant Temperature...

Page 68: ...t function button To return to previous display press the Previous function button To return to the 6 Up Display press the View function button Air Pressure display does not appear if the air pressure...

Page 69: ...ars and begins to flash when fuel level reaches 10 It continues to flash until fuel level falls to 0 4 Yellow LED The yellow LED begins to flash when the low fuel warning appears It con tinues to flas...

Page 70: ...r according to the J1939 standard Typical faults are listed in Table 12 1 9 Diagnostic Description 10 Occurrence Count For non critical faults the number of occurrences can accumulate 11 Previous Func...

Page 71: ...e by the engine Factory Authorized Service Agent only Attempting engine repair may void engine warranty 1 Diagnostic Display 2 Indicates Number Of Faults 3 Suspect Parameter Number 4 Failure Mode Iden...

Page 72: ...tion Button 1 ENTER PASSWORD 0000 Cancel Enter 2 3 4 5 6 12 13 Main Menu Options Resetting Hours At Oil Change 1 Main Menu 2 Cursor 3 Scroll Function Buttons Use scroll function buttons to move cursor...

Page 73: ...ion buttons to in crease or decrease display bright ness When desired percentage is reached press Select function but ton 6 Contrast Menu Display Use scroll function buttons to in crease or decrease d...

Page 74: ...val can be modified Shorter service inter vals may be appropriate during heavy use or in certain environ ments such as dusty or extreme temperatures Lengthening ser vice intervals is not recommended a...

Page 75: ...may be requested by a Factory Author ized Service Agent during troubleshooting 7 Stored Codes Stored codes can also be accessed when the initial Service Reminder display appears as the engine con trol...

Page 76: ...g run in period to properly seat piston rings and prevent wetstacking See name plate rating label or specifications section in this manual to find rated voltage and current NOTICE Do not idle engine l...

Page 77: ...eter as shown if not provided on generator Start engine and run for several minutes For Load Bank Set load bank switches and then adjust generator A V control so load equals rated voltage and current...

Page 78: ...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 79: ...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 80: ...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 81: ...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 82: ...t 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 Vo...

Page 83: ...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 84: ...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 85: ...OM 262 752 Page 81 Notes...

Page 86: ...OM 262 752 Page 82 Notes...

Page 87: ...rts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work stati...

Page 88: ...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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