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TABLE OF CONTENTS

SECTION 6 − OPERATING WELDING GENERATOR

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6-1.

Front Panel Controls (See Section 6-2)

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6-2.

Description Of Front Panel Controls (See Section 6-1)

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6-3.

Engine Starting Sequence

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6-4.

Process/Contactor Switch

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6-5.

Arc Control

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6-6.

Low Open-Circuit Voltage (VRD) Switch Mode

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6-7.

Stick Start Procedure − Scratch Start Technique

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6-8.

Lift-Arc

TIG With Auto-Stop

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6-9.

Remote Voltage/Amperage Control

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6-10. Engine Block Heater Operation

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SECTION 7 − OPERATING AUXILIARY EQUIPMENT

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7-1.

Auxiliary Power Receptacles

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7-2.

GFCI Receptacle Information, Resetting And Testing

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SECTION 8 − MAINTENANCE

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8-1.

Routine Maintenance

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8-2.

Checking Generator Brushes

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8-3.

Battery Replacement

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8-4.

Servicing Air Cleaner

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8-5.

Engine Speed Adjustment

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8-6.

Oil Specifications

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8-7.

Servicing Fuel And Lubrication Systems

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8-8.

Engine/Generator Overload Protection

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8-9.

Voltmeter/Ammeter Help Displays

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SECTION 9 − TROUBLESHOOTING

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9-1.

Troubleshooting

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SECTION 10 − PARTS LIST

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10-1. Recommended Spare Parts

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SECTION 11 − ELECTRICAL DIAGRAMS

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SECTION 12 − ENGINE INFORMATION DISPLAY

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SECTION 13 − RUN-IN PROCEDURE

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13-1. Wetstacking

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13-2. Run-In Procedure Using Load Bank Or Resistance Grid

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SECTION 14 − GENERATOR POWER GUIDELINES

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COMPLETE PARTS LIST − Available at www.MillerWelds.com

WARRANTY

Содержание Big Blue 800 DUO PRO

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 85: ...OM 262 752 Page 81 Notes...

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

Страница 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...

Страница 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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