1. Manuals
  2. Brands
  3. Miller Manuals
  4. Welding System
  5. Big Blue 500 Pro
  6. Owner's manual

Miller Big Blue 500 Pro Owner's Manual

Hide thumbs Also See for Big Blue 500 Pro:
Table of Contents

Advertisement

Quick Links

For product information,
Owner's Manual translations,
and more, visit
www.MillerWelds.com
Big Blue 500 Pro
Big Blue 600 Pro
Kubota
OM-278739F
Processes
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welder/Generator
)
)
File: Engine Drive
2018−06

Advertisement

Table of Contents
loading

Related Manuals for Miller Big Blue 500 Pro

Summary of Contents for Miller Big Blue 500 Pro

  • Page 1 Flux Cored (FCAW) Welding Stick (SMAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welder/Generator Big Blue 500 Pro Big Blue 600 Pro Kubota File: Engine Drive For product information, Owner’s Manual translations, and more, visit...
  • 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 6 − OPERATING WELDER/GENERATOR ..........6-1.

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

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2018−01 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 Watch for fire, and keep a fire extinguisher nearby. FLYING METAL or DIRT can injure D Be aware that welding on a ceiling, floor, bulkhead, or partition can eyes. cause fire on the hidden side. D Do not cut or weld on tire rims or wheels. Tires can explode if heat- D Welding, chipping, wire brushing, and grinding ed.

  • 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 Diesel Engines: WARNING: Breathing diesel engine exhaust exposes you to WARNING: This product can expose you to chemicals in- chemicals known to the state of California to cause cancer cluding lead, which are known to the state of California to and birth defects or other reproductive harm.

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

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION rom_2018−01_fre 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 Ne pas raccorder plus d’une électrode ou plus d’un câble de LES ACCUMULATIONS DE GAZ masse à une même borne de sortie de soudage. Débrancher le risquent de provoquer des blessures câble pour le procédé non utilisé. ou même la mort. D Utiliser une protection GFCI lors de l’utilisation d’appareils auxi- liaires.

  • 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 Ne pas approcher les mains, cheveux, vêtements lâches et outils cisé autrement dans la section maintenance du manuel du des organes mobiles. moteur). D Si le moteur est chaud et que le liquide doit être vérifié, opérer com- D Remettre en place les portes, panneaux, recouvrements ou me suivant.

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

    détendre la pression et s’assurer que le circuit d’air ne peut être L’INHALATION D’AIR COMPRIMÉ risque mis sous pression par inadvertance. de provoquer des blessures ou même D Demander seulement à un personnel qualifié d’enlever la mort. les dispositifs de sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.
  • Page 16 D Débrancher le câble négatif (−) en premier lieu. Le rebrancher en UNE REMORQUE QUI BASCULE peut dernier lieu. provoquer des blessures. D Les sources d’étincelles, flammes nues, cigarettes et autres D Utiliser les supports de la remorque ou des sources d’inflammation doivent être maintenues à...

  • Page 17: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements Pour les moteurs diesel : AVERTISSEMENT : ce produit peut vous exposer à des pro- duits chimiques tels que le plomb, reconnus par l’État de AVERTISSEMENT : les gaz d’échappement de moteurs diesel Californie comme cancérigènes et sources de malformations vous exposent à...
  • Page 18 OM-278739 Page 14...

  • Page 19: Section 3 − Definitions

    Complete Parts List available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2017−04 Protect yourself from electric shock by insulating yourself from work and ground.
  • Page 20 Complete Parts List available at www.MillerWelds.com Do not work on unit if engine is running. Stop engine first. Safe21 2017−04 Do not smoke while fueling or if near fuel. Safe22 2017−04 Stop engine before fueling. Safe23 2017−04 Do not fuel a hot engine. Safe24 2017−04 Use lift eye to lift unit and properly installed accessories only, not gas cylinders.

  • Page 21: Miscellaneous Symbols And Definitions

    Complete Parts List available at www.MillerWelds.com Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Become trained and read the instructions before working on the machine or welding. Safe40 2012−05 Engine fuel plus flames or sparks can cause fire. Safe45 2012−05 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler.
  • Page 22 Complete Parts List available at www.MillerWelds.com Positive Engine Coolant Rated Idle Speed Direct Current Battery (Engine) Duty Cycle (DC) Alternating Current (AC) Engine Hours Protective Earth Maximum Power (Ground) Engine Consumption 1max Single Phase Engine−Driven Engine 3−Phase Alternator with Rectifier Three Phase Engine Start Circuit Breaker...

  • Page 23: Section 4 − Specifications

    Complete Parts List available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Locations The serial number and rating information for this product is located on the right side. Use rating label to determine input power requirements and/or rated output.

  • Page 24: Duty Cycle And Overheating

    This unit is rated for welding at 500 amperes continuously. NOTICE − Exceeding duty cycle can damage unit and void warranty. Big Blue 500 Pro Models Big Blue 600 Pro Models 272798-A / 275897-A 4-6. Fuel Consumption The curve shows typical fuel use under weld or power loads.

  • Page 25: Volt-Ampere Curves (Big Blue 600 Models)

    Complete Parts List available at www.MillerWelds.com 4-7. Volt-Ampere Curves (Big Blue 600 Models) A. Stick The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welder/generator. Curves of other settings fall between the curves shown. DC Amperes B.

  • Page 26: Volt-Ampere Curves (Big Blue 500 Models)

    Complete Parts List available at www.MillerWelds.com 4-8. Volt-Ampere Curves (Big Blue 500 Models) A. Stick The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welder/generator. Curves of other settings fall between the curves shown. DC AMPERES B.

  • Page 27: Generator Power Curves

    Complete Parts List available at www.MillerWelds.com 4-9. Generator Power Curves A. Single Phase 4 kW The AC power curves show the generator output in amperes. AC Amperes B. Three Phase 20 kW AC Amperes C. Single Phase 12 kW AC Amperes 272 796-A OM-278739 Page 23...

  • Page 28: Section 5 − Installation

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

  • Page 29: Grounding Generator To Truck Or Trailer Frame

    Complete Parts List available at www.MillerWelds.com 5-2. Grounding Generator To Truck Or Trailer Frame GND/PE rot_grnd2 2018−01 − 800652-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 shock and static electricity hazards.

  • Page 30: Connecting The Battery

    Complete Parts List available at www.MillerWelds.com 5-4. Connecting The Battery − Tools Needed: 1/2 in. Conn_batt1 2014−06 802 168-E / S-0756-C NOTICE − Lead acid batteries discharge Battery is most easily accessed through Never start the engine when the when stored in any temperature. Units that the rear panel.

  • Page 31: Engine Prestart Checks

    Full Diesel Full 907736 / 255 549 NOTICE − Diesel engines in Miller equip- face. If oil is not up to full mark on dipstick, Check all engine fluids daily. ment are meant to operate optimally at mod- add oil (see maintenance label).

  • Page 32: Weld Output Terminals

    Complete Parts List available at www.MillerWelds.com 5-6. Weld Output Terminals Tools Needed: 3/4 in. 907736 right. work cable to Negative (−) terminal on Stop engine. right. Use Process/Contactor switch to se- For Stick and TIG Direct Current Electrode Turn off power before connecting to lect type of weld output (see Section 6-4).

  • Page 33: Selecting Cable Sizes

    Complete Parts List 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 34: Section 6 − Operating Welder/Generator

    Complete Parts List available at www.MillerWelds.com SECTION 6 − OPERATING WELDER/GENERATOR 6-1. Front Panel Controls (See Section 6-2) 276677-A / 907736 OM-278739 Page 30...

  • Page 35: Description Of Front Panel Controls (See Section 6-1)

    Adjust control to adjust preset voltage. defaults to preset amperage. NOTICE − Diesel engines in Miller equipment Select Button Arc Control Meter are meant to operate optimally at moderate to Push the control to use as Select button.

  • Page 36: Engine Starting Sequence

    Complete Parts List available at www.MillerWelds.com 6-3. Engine Starting Sequence Wait to Start/Preheating Service Reminder Remaining Remaining Service Reminder Engine Oil Engine Oil Compressor Oil Compressor Oil NOTICE − Do not use ether or other start- Engine Control switch is placed in the Run be started.

  • Page 37: Process/Contactor Switch

    Complete Parts List available at www.MillerWelds.com 6-4. Process/Contactor Switch Process/Contactor Switch Weld output terminals are energized when Process/ Contactor switch is in an Electrode Hot position and the engine is running. Use switch to select weld process and weld output on/off control (see table below).

  • Page 38: Service Menu

    Complete Parts List available at www.MillerWelds.com 6-5. Service Menu Adjust Control/Select Button Press and hold control for 5 seconds, then release to access the Service Menu. Rotate the knob to scroll through the menu items. Press and release the control to access the op- tions and information within each menu item.

  • Page 39: Arc Control Settings

    6-6. Arc Control Settings Arc Control is not active when the Process/Contactor switch is in the following positions: Electrode Hot − CAC-A (Air Carbon Arc Gouging) Remote ON/OFF GTAW (Remote TIG) Miller recommends Hobart filler metals. Process/Contactor Switch Arc Control SOFT Starting point for stainless steel wire (high inductance) (−25 to −1)

  • Page 40: Dynamic Dig Settings

    Complete Parts List available at www.MillerWelds.com Process/Contactor Switch Arc Control SOFT Starting point for stainless steel wire (high inductance) (−25 to −1) SOFT L (0) Starting point for mild steel wire STIFF Starting point for aluminum wire (low inductance). (1 to 25) STIF Starting point for dual shield flux core, vertical overhead Wire feeder connects to...

  • Page 41: Stick Start Procedure − Scratch Start Technique

    Auto-Crater. Arc End With Auto-Crater While welding. Lift torch slightly to start Auto-Crater end (current is reduced). Lower torch. Weld current ramps down. Shielding gas continues until shut off. Miller recommends Hobart filler metals. WM Marketing OM-278739 Page 37...

  • Page 42: Voltage/Amperage Control With 14-Pin Remote Accessory

    Complete Parts List available at www.MillerWelds.com 6-10. Voltage/Amperage Control With 14-Pin Remote Accessory Remote Receptacle Connect optional remote control to receptacle (see Section 5-9). When a remote control is con- nected to the Remote recep- tacle, the Auto Remote Sense feature automatically switches voltage/amperage control to the remote control.

  • Page 43: Operating Engine Block Heater

    Complete Parts List available at www.MillerWelds.com 6-11. Operating Engine Block Heater Engine Block Heater Plug Use heater to maintain a constant engine coolant temperature. To turn on heater, connect heater plug to 120 volts AC receptacle. Heater Specifications Do not run engine while en- gine block heater is on.

  • Page 44: Updating Software

    Complete Parts List available at www.MillerWelds.com 6-12. Updating Software Obtain the latest firmware to be loaded When the machine has powered up, if valid During the download, the left meter display from MillerWelds.com. files exist on the flash drive, the user is indicates the active download with ALLC, prompted to confirm the start of the down- ALLW, AL C, or AL W.

  • Page 45: Summary File

    Complete Parts List available at www.MillerWelds.com 6-13. Summary File Summary File Each time a USB stick is inserted in the USB receptacle, a summa- ry file is saved to the USB stick as SummaryFile.txt. “USB ACC” will display as the file is written.

  • Page 46: Associating Arcreach Devices (Arcreach Models Only)

    Complete Parts List available at www.MillerWelds.com 6-14. Associating ArcReach Devices (ArcReach Models Only) Stop engine. NOTICE − Do not exceed machine duty cycle. Associating ArcReach Device To Engine Driven Welder/Generator Make connections between welder/generator and ArcReach device. See Owner’s Manual for ArcReach device for typical connection diagrams.

  • Page 47: Section 7 − Operating Auxiliary Equipment

    Complete Parts List available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles 271 858-B Single-Phase Generator Power CB6 protects RC1 and RC2, and the gen- (240 V x 13 A) + (120 V x 7 A) = erator winding from overload.

  • Page 48: Gfci Receptacle Information, Resetting, And Testing

    Complete Parts List 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 2018-01 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 49: Section 8 − Maintenance & Troubleshooting

    Complete Parts List available at www.MillerWelds.com SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Maintenance Label OM-278739 Page 45...

  • Page 50: Cleaning Unit

    Complete Parts List available at www.MillerWelds.com 8-2. Cleaning Unit Clean unit exterior, including stainless steel if so equipped, frequently to prevent rust. NOTICE − Use of a power washer is acceptable; however, cover or avoid electrical parts and the Engine Control Unit (ECU) located on the lower left side of the center upright.

  • Page 51: Servicing Air Cleaner

    Complete Parts List 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 52: Checking Generator Brushes

    Complete Parts List available at www.MillerWelds.com 8-5. Checking Generator Brushes Stop engine and let cool. Generator Brush Mark and disconnect leads at brushhold- er cap. Remove brushes. Minimum Length: Replace brushes if damaged or if brush 5/8 in. (16 mm) material is at or near minimum length.

  • Page 53: Battery Maintenance

    Complete Parts List available at www.MillerWelds.com 8-7. Battery Maintenance Lead acid batteries discharge 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 54: Servicing Fuel And Lubrication Systems

    Complete Parts List available at www.MillerWelds.com 8-10. Servicing Fuel And Lubrication Systems Tools Needed: 907736 To replace fuel filters: Once the air has escaped, fuel will begin to Stop engine and let cool. seep out of the spout and from underneath For primary fuel filter, disconnect water sen- the air bleed screw on the secondary fuel fil- After servicing, start engine and...

  • Page 55: Engine/Generator Overload Protection

    Complete Parts List available at www.MillerWelds.com 8-11. Engine/Generator Overload Protection 907736 / Ref. 272388-TP1 CB3 protects the weld control circuit. If CB10 automatically resets when the fault is Stop engine. CB3 opens, weld output stops, meters will corrected. be blank; however, generator power is still When a supplementary protector, cir- Circuit Breaker CB13 (Not Shown) available.

  • Page 56: Voltmeter/Ammeter Error Displays

    Complete Parts List available at www.MillerWelds.com 8-12. Voltmeter/Ammeter Error Displays IGBT TEMP Display Example Use the Voltmeter/Ammeter error displays to diagnose and correct fault conditions. When an error is displayed, normally weld output has stopped but generator power output may be okay. To reset error displays, stop unit and then restart.

  • Page 57: Troubleshooting

    Complete Parts List available at www.MillerWelds.com 8-13. Troubleshooting Also see Voltmeter/Ammeter error displays to assist in troubleshooting weld problems (see Section 8-12). Also see Engine Information Display to assist in troubleshooting engine related problems (see Section 11). A. Welding Trouble Remedy No weld output;...
  • Page 58 Complete Parts List available at www.MillerWelds.com B. Standard Generator Power Trouble Remedy No generator power output at AC recept- Reset receptacle supplementary protectors. Reset GFCI receptacle. acles; weld output okay. Check fuse F1, and replace if open (see Section 8-11). Have Factory Authorized Service Agent check integrated rectifiers SR1 and SR2, resistor R3, and capacitor C6.

  • Page 59: Section 9 − Parts List

    Complete Parts List available at www.MillerWelds.com Trouble Remedy Engine suddenly stops. Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature is too high (see Section 5-5). Automatic shutdown system is inhibited for 30 seconds after start-up. See engine manual.

  • Page 60: Section 10 − Electrical Diagrams

    SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welder/Generator OM-278739 Page 56...
  • Page 61 277098-C OM-278739 Page 57...

  • Page 62: Section 11 − Engine Information Display

    SECTION 11 − ENGINE INFORMATION DISPLAY The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 11-1. Display Layout And Controls Engine Information Display Engine Control Switch Function Buttons Yellow LED Red LED The Engine Information Display...
  • Page 63 11-3. RPM Signal Failed Display RPM Signal Failed Display If the operator places the Engine Control switch in the Run/Idle or Run position and does not start the engine, a timer starts. If this condi- tion exists for 30 minutes or longer, the RPM signal failed message ap- pears.
  • Page 64 11-5. 6-Up Display n/min 6-Up Display With Engine RPM 6-Up Display With Air Compressor Engine Coolant Temperature Pressure (Models With Air Engine RPM Compressor) This is the default screen configuration. If Compressor Air Pressure The air compressor must be on and air the operator wants to toggle to the 1-Up Battery Voltage pressure must be available for this display...
  • Page 65 11-7. 1-Up Displays 1-Up Machine Hours Display To go to the next display, press the Next function button. To return to previous display, press the Previ- ous function button. To return to the 6-Up Display, press the View function button. Machine Hours 15 18 Battery Potential...
  • Page 66 11-8. 1-Up Compressor Displays Air Compressor Pressure 1-Up Display To increment to the next display, press the Next 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 input is less than 50 PSI.
  • Page 67 11-9. Fuel Level Warnings Fuel level warnings are generat- ed by sensors at the fuel tank. All engine warnings that are dis- played are generated by the en- gine controller (see Sections 11-10 and 11-11). 6-Up Display 1-Up Fuel Level Display Low Fuel Warning The low fuel warning indicator ap- pears and begins to flash when fuel...
  • Page 68 11-10. Warning or Shutdown Display Oil Pressure Display Fault Warning Indicator The warning symbol appears on the display when an engine condition approaches a shutdown condition. 45 60 Fault Shutdown Indicator The shutdown symbol appears on the display when a severe engine fault can cause shutdown.
  • Page 69 Table 11-1. Fault Descriptions This is an abbreviated list of faults. These faults can commonly be remedied by the operator. If other faults appear, contact Factory Authorized Service Agent. Description of Fault Tier 3 or Tier 4 Interim Engines Low oil pressure; warning threshold exceeded High coolant temperature;...
  • Page 70 11-12. Main Menu Access Code Access Code Display An access code is required to gain access to the main menu. This dis- play appears whenever the Menu/ Cancel function button is pressed while in the 1-Up or 6-Up display ENTER PASSWORD Access Code (Password) The factory set access code is 1000.
  • Page 71 11-14. Main Menu Options: Brightness, Contrast, And Units Main Menu Cursor Scroll Function Buttons Use scroll function buttons to move cursor. Select Function Button When the cursor is in desired posi- Brightness " tion, press Select function button to go to sub-menu. Contrast Brightness Menu Display Units...
  • Page 72 11-15. Main Menu Options − Reminders Main Menu Cursor Scroll Function Buttons Use scroll function buttons to move cursor. Select Function Button When the cursor is in desired posi- tion, press Select function button to Brightness go to sub-menu. Contrast Service Reminders Display Units English...
  • Page 73 11-16. Main Menu Options − OEM, Version, Stored Codes, And Language Main Menu Cursor Scroll Function Buttons Use scroll function buttons to move cursor. Select Function Button When the cursor is in desired posi- tion, press Select function button to go to sub-menu.

  • Page 74: Section 12 − 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 75: Run-In Procedure Using Load Bank Or Resistance Grid

    12-2. 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 76: Section 13 − Generator Power Guidelines

    SECTION 13 − 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. 13-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
  • Page 77 13-3. 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 78 13-5. 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 79 13-7. 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 80 13-8. 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 81 13-10. 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 82 13-11. 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 83 Effective January 1, 2018 (Equipment with a serial number preface of MJ 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 84 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 2018 Miller Electric Mfg. LLC 2018−01...

This manual is also suitable for:

Big blue 600 pro

Table of Contents