Miller Big Blue 450 Duo CST Owner's Manual
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Miller Big Blue 450 Duo CST Owner's Manual

Engine driven welder/generator
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Big Blue 450 Duo CST
®
OM-266621D
2017−10
Processes
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Engine Driven Welder/Generator
File: Engine Drive

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Summary of Contents for Miller Big Blue 450 Duo CST

  • Page 1 OM-266621D 2017−10 Processes Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Engine Driven Welder/Generator Big Blue 450 Duo CST ® File: Engine Drive For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING ......... 8-1.

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

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury.
  • Page 6 D Be alert that welding sparks and hot materials from welding can FLYING METAL or DIRT can injure easily go through small cracks and openings to adjacent areas. eyes. D Watch for fire, and keep a fire extinguisher nearby. D Welding, chipping, wire brushing, and grinding D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause sparks and flying metal.

  • Page 7: Engine Hazards

    1-3. Engine Hazards EXHAUST SPARKS can cause fire. BATTERY EXPLOSION can injure. D Do not let engine exhaust sparks cause fire. D Always wear a face shield, rubber gloves, and D Use approved engine exhaust spark arrestor in protective clothing when working on a battery. required areas —...

  • Page 8: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and MOVING PARTS can injure. gouging can cause fire or explosion. D Keep away from moving parts such as fans, D Do not cut or gouge near flammables. belts and rotors. D Watch for fire; keep extinguisher nearby. D Keep all doors, panels, covers, and guards closed and securely in place.
  • Page 9 BATTERY CHARGING OUTPUT and BATTERY STATIC (ESD) can damage PC boards. EXPLOSION can injure. D Put on grounded wrist strap BEFORE handling Battery charging not present on all models. boards or parts. D Use proper static-proof bags and boxes to D Always wear a face shield, rubber gloves, and store, move, or ship PC boards.

  • Page 10: California Proposition 65 Warnings

    1-6. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 D Utiliser une protection différentielle lors de l’utilisation d’un équi- LES ACCUMULATIONS DE GAZ pement auxiliaire. Ne pas tester ni réarmer les prises femelles risquent de provoquer des blessures avec différentiel au régime de ralenti/en basse tension: cela ou même la mort. endommagerait le disjoncteur différentiel, qui ne remplirait plus son rôle de protection contre une électrocution causée par un D Fermer l’alimentation du gaz comprimé...

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    D Porter un équipement de protection pour le corps fait d’un matériau Si des BOUTEILLES sont endomma- résistant et ignifuge (cuir, coton robuste, laine). La protection du gées, elles pourront exploser. corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.

  • Page 14: Dangers Liés À L'air Comprimé

    D Pour empêcher tout démarrage accidentel pendant les travaux D Toujours vérifier le niveau de liquide de refroidissement dans le d’entretien, débrancher le câble négatif (−) de batterie de la borne. vase d’expansion (si présent), et non dans le radiateur (sauf si pré- cisé...

  • Page 15: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Pour rechercher des fuites, utiliser de l’eau savonneuse ou D Ne pas approcher les mains, cheveux, vêtements lâches et outils un détecteur à ultrasons, jamais les mains nues. En cas des organes mobiles. de détection de fuite, ne pas utiliser l’équipement. D Avant d’intervenir sur le circuit d’air comprimé, couper l’alimentation électrique, verrouiller et étiqueter l’appareil, D Remettre les portes, panneaux, recouvrements ou dispositifs...
  • Page 16 D Réduire le courant ou le facteur de marche avant de poursuivre le LA SORTIE DE RECHARGE et L’EXP- soudage. LOSION DE LA BATTERIE peuvent D Ne pas obstruer les passages d’air du poste. provoquer des blessures. LES CHARGES ÉLECTROSTATI- La recharge de batterie n’existe pas sur tous les QUES peuvent endommager les modèles.

  • Page 17: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements Pour les moteurs à essence : Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques Les gaz d’échappement des moteurs contiennent des pro- dont l’État de Californie reconnaît qu’ils provoquent des mal- duits chimiques dont l’État de Californie reconnaît qu’ils formations congénitales et, dans certains cas, des cancers.
  • Page 18 OM-266621 Page 14...

  • Page 19: Section 3 − Definitions

    Complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. Safe46 2012−05 Read Owner’s Manual. Read labels on unit. Safe47 2012−05 Read Owner’s Manual.

  • Page 20: Symbols And Definitions

    Complete Parts List is available at www.MillerWelds.com Do not spray water on CST units. Safe92 2017−04 Door must be fully open during operation. Safe93 2012−08 3-2. Symbols And Definitions Alternating Amperes Current Check Air Cleaner Circuit Protection Volts Protective Earth Battery (Engine) (Ground) Hertz...

  • Page 21: Section 4 − Specifications

    Lifting Eye Weight Rating: 2000 lb (907 kg) Maximum For information on specifications and performance data pertaining to standard CST units operating individually, see Miller Owner’s Manual OM-217655. Use this Owner’s Manual in conjunction with OM-217655 for operation, maintenance, and troubleshooting.

  • Page 22: Environmental Specifications

    Complete Parts List is available at www.MillerWelds.com 4-4. Environmental Specifications A. IP Rating IP Rating IP23S This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless sheltered.
  • Page 23 Complete Parts List is available at www.MillerWelds.com C. Stick Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. XX10 Stick Mode EXX10 SOFT MIN EXX10 STIFF MIN EXX10 SOFT MAX...
  • Page 24 Complete Parts List is available at www.MillerWelds.com D. TIG Volt Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. Amps DC Amperes 266 431-A E.

  • Page 25: Section 5 − Installation

    Complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Installing Welder/Generator Airflow Clearance 18 in. Movement (460 mm) 18 in. 18 in. (460 mm) (460 mm) 18 in. 18 in. (460 mm) (460 mm) Location/Mounting Bolting Welding Unit In Unit In Place...

  • Page 26: Installing Exhaust Pipe

    Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator To Truck Or Trailer Frame GND/PE rot_grnd2 2014−11 − 800 652-D frame. Always connect a ground Equipment Grounding Terminal (On Always ground generator frame to wire from the generator equipment Front Panel) vehicle frame to prevent electric grounding terminal to bare metal on...

  • Page 27: Connecting The Battery

    Automatic Shutdown System Automatic shutdown system stops en- Use fuel formulated for cold weather NOTICE − Diesel engines in Miller equip- gine if oil pressure is too low or coolant (diesel fuel can gel in cold weather). ment are meant to operate optimally at temperature is too high.

  • Page 28: Engine Fuel And Coolant Prestart Information

    Complete Parts List is available at www.MillerWelds.com 5-6. Engine Fuel And Coolant Prestart Information Check radiator coolant level when fluid is low in Full recovery tank. Full Diesel Engine stops if fuel level is low. Capacity: 6 qt (5.7 L) Coolant Recovery Tank Full Cold...

  • Page 29: Selecting Cable Sizes

    Complete Parts List is available at www.MillerWelds.com 5-8. Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 30: Making Dual Operator Cc Weld Connections With Common Work Cables

    Complete Parts List is available at www.MillerWelds.com 5-10. Making Dual Operator CC Weld Connections With Common Work Cables 907 477 / Ref. 801 701 expected amperage and that the junction is Electrode Holder Cables For DCEP Stop engine. properly insulated. Common Work Cable Failure to properly size and connect NOTICE −...

  • Page 31: Paralleling Cst Units For Smaw Welding

    Complete Parts List is available at www.MillerWelds.com 5-11. Paralleling CST Units For SMAW Welding 907 477 / Ref. 801 701 NOTICE − When using these connections For Stick welding Direct Current Electrode Stop engine. common work terminal, Positive (DCEP), connect common work Failure to properly size and connect connections must be of the same polarity.

  • Page 32: Section 6 − Operation

    Complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATION 6-1. Front Panel Engine Controls (See Section 6-2) 907 477 / Ref 264 783 6-2. Description Of Front Panel Engine Controls (See Section 6-1) Engine Starting Controls Above 325 F (05 C): turn Engine Control Fuel Gauge/Hourmeter switch to Start.

  • Page 33: Operating Optional Engine Block Heater

    Complete Parts List is available at www.MillerWelds.com 6-3. Operating Optional Engine Block Heater Engine Block Heater Plug Use heater to maintain a constant engine coolant temperature. To turn on heater, connect heater Coolant Heater plug to 120 volts AC receptacle. Specifications Do not run engine while en- ±...

  • Page 34: Fuel/Hour Gauge Descriptions

    Complete Parts List is available at www.MillerWelds.com 6-4. Fuel/Hour Gauge Descriptions OM-266621 Page 30...

  • Page 35: Front Panel Cst Controls

    Complete Parts List is available at www.MillerWelds.com 6-5. Front Panel CST Controls A. Overview Output Indicator Light Amperage Control Green on nameplate indicates a TIG When unit is first energized this indicator See Section C. function and Gray indicates a Stick light flashes several times and then High Temperature Shutdown Light function.
  • Page 36 Complete Parts List is available at www.MillerWelds.com B. Process Select Control Process Select Control Rotate knob to select desired process. Lift-Arct TIG - Normal open-circuit voltage is not present between electrode workpiece. A solid-state contactor does not energize until after the electrode touches the workpiece, RECOMMENDED PROCESS preventing overheating, sticking, or...

  • Page 37: Section 7 − Operating Auxiliary Equipment

    Complete Parts List is available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles 264 783 not work. Place CB6 switch in On position Use GFCI protection when operat- Test GFCI monthly. See Section 7-2 to reset circuit breaker. ing auxiliary equipment.

  • Page 38: Gfci Receptacle Information, Resetting, And Testing

    Complete Parts List is available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting, And Testing Alternate location for red and green indicator LEDs. Orientation of receptacle may be different in other applications. RotGFCI1 2017-10 If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles Use GFCI protection when operat- button pops out, and the circuit opens to...

  • Page 39: Section 8 − Maintenance & Troubleshooting

    Complete Parts List is available at www.MillerWelds.com SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Maintenance Label Mitsubishi Engine North America 1250 Greenbriar Dr., Suite E Addison, IL 60101 630−268−0750 Http://www.mitsubishi−engine.com Use web site to locate closest dealer. For in- ternational information, use: Http://www.mhi-global.com OM-266621 Page 35...

  • Page 40: Routine Maintenance

    Complete Parts List is available at www.MillerWelds.com 8-2. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions. n = Check Z = Change ~ = Clean l = Replace...

  • Page 41: Servicing Air Cleaner

    Complete Parts List is available at www.MillerWelds.com 8-4. Servicing Air Cleaner Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each...

  • Page 42: Battery Maintenance

    Complete Parts List is available at www.MillerWelds.com 8-5. Battery Maintenance Lead acid batteries discharged when stored in any temperature. Units that are stored should have the battery recharged every three months and before being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open−circuit voltage drops to 12.4 volts DC when measured across the battery terminals.

  • Page 43: Servicing Engine Cooling System

    Complete Parts List is available at www.MillerWelds.com 8-8. Servicing Engine Cooling System Stop engine and let cool. Radiator Cap Cover Radiator Draincock Coolant Recovery Tank Change coolant according to engine manual. Add coolant according to engine maintenance label. Check coolant level in recovery tank daily.

  • Page 44: Servicing Fuel And Lubrication Systems

    Complete Parts List is available at www.MillerWelds.com 8-10. Servicing Fuel And Lubrication Systems 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. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary (Canister) Fuel Filter...

  • Page 45: Overload Protection

    Primary Fuses F2 Thru F7 Supplementary Protector CB2 power output may stop. Supplementary Protector CB3 Primary fuses are 30 A, 250 V, Slo Blo Press button to reset supplementary pro- fuses, Miller Part No. 247 869. Circuit Breaker CB1 tector. OM-266621 Page 41...

  • Page 46: Troubleshooting Cst

    Complete Parts List is available at www.MillerWelds.com 8-12. Troubleshooting CST Output LED (Blue) High Temperature LED (Yellow) 803 942-A Repeated LED Flashes Indicate Status Blue Yellow Trouble Possible Causes Remedy Check and replace line fuses, if neces- None None Blown fuses. sary (see Section 8-11).

  • Page 47: Troubleshooting Generator

    Complete Parts List is available at www.MillerWelds.com Repeated LED Flashes Indicate Status Blue Yellow Trouble Possible Causes Remedy Single phase rating Reduce output to 200 amperes or less. exceeded. Output foldback Check auxiliary power output to verify Reduced weld due to exces- 230 volts AC is available.
  • Page 48 Complete Parts List is available at www.MillerWelds.com B. Engine Trouble Remedy Engine will not crank. Check battery, and replace if necessary. Check battery connections and tighten if necessary. Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-11). Have Factory Authorized Service Agent check engine wiring harness and components.

  • Page 49: Section 9 − Parts List

    Complete Parts List is available at www.MillerWelds.com SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Dia. Part Mkgs. Description Quantity ....085874 Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt .

  • Page 50: Section 10 − Electrical Diagrams

    SECTION 10 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator OM-266621 Page 46...
  • Page 51 247 963-D OM-266621 Page 47...

  • Page 52: Section 11 − Run-In Procedure

    2014−09 NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.

  • Page 53: Run-In Procedure Using Load Bank Or Resistance Grid

    11-2. Run-In Procedure Using Load Bank Or Resistance Grid S-0683 / S-0684 Stop engine. Weld Cables voltage and current of the generator (see nameplate, rating label, or the Resistance Grid Do not touch hot exhaust pipe, en- specifications section in this manual). gine parts, or load bank/grid.

  • Page 54: Section 12 − Generator Power Guidelines

    SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 12-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
  • Page 55 12-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. GND/PE Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
  • Page 56 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 57 12-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment Rating Starting Watts Running Watts Hand Drill 1/4 in. 3/8 in. 1/2 in. Circular Saw 6-1/2 in. 7-1/4 in. 8-1/4 in. 1400 1400 Table Saw 9 in. 4500 1500 10 in. 6300 1800 Band Saw...
  • Page 58 12-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
  • Page 59 12-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install, ground, and operate this equipment ac- cording Owner’s Manual and national, state, and local codes. Customer-supplied equipment is required if generator will sup- ply standby power during Fused...
  • Page 60 12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten- sion cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm Current Load (Watts)
  • Page 61 Notes...
  • Page 62 Notes...
  • Page 63 Effective January 1, 2017 (Equipment with a serial number preface of MH or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 64 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2017 Miller Electric Mfg. Co. 2017−01...

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