Page 1
OM-244 023B 2011−03−21 Processes Stick (SMAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator Big Blue 800 ® File: Engine Drive Visit our website at 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 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ....... . 1-1.
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2010−03 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 Do not weld on closed containers such as tanks, drums, or pipes, FUMES AND GASES can be hazardous. unless they are properly prepared according to AWS F4.1 (see Safety Standards). Welding produces fumes and gases. Breathing these D Do not weld where the atmosphere may contain flammable dust, fumes and gases can be hazardous to your health.
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 protective clothing when working on a battery. D Use approved engine exhaust spark arrestor in required areas —...
1-4. Hydraulic Hazards D HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics HYDRAULIC EQUIPMENT can injure near sparks or flames; do not smoke near hydraulic fluid. or kill. D Reinstall doors, panels, covers, or guards when servicing is D Incorrect installation or operation of this unit finished and before starting unit.
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.
WELDING WIRE can injure. H.F. RADIATION can cause interference. D Do not press gun trigger until instructed to do D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Do not point gun toward any part of the body, other people, or any metal when threading D Have only qualified persons familiar with welding wire.
1-8. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- from Global Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org). www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, from National Fire Protection Association, and Cutting, American Welding Society Standard AWS F4.1, from Glob-...
SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2010−03 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 13
D Porter un casque de soudage approuvé muni de verres filtrants LES PIÈCES CHAUDES peuvent approprié pour protéger visage et yeux pour protéger votre visage provoquer des brûlures. et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré...
D Placer les bouteilles debout en les fixant dans un support station- Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) naire ou dans un porte-bouteilles pour les empêcher de tomber ou peuvent affecter les implants médicaux. de se renverser. D Tenir les bouteilles éloignées des circuits de soudage ou autres D Les porteurs de stimulateurs cardiaques et circuits électriques.
D Mettre des lunettes de sécurité et des gants, placer un torchon sur LES ÉTINCELLES À L’ÉCHAPPEMENT le bouchon du radiateur. peuvent provoquer un incendie. D Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. D Empêcher les étincelles d’échappement du moteur de provoquer un incendie.
un médecin familiarisé avec ce type de blessure, faute de quoi LES PIÈCES ET LIQUIDES CHAUDS la gangrène pourrait apparaître. peuvent provoquer des brûlures. Les PIÈCES MOBILES peuvent causer D Ne pas toucher les pièces chaudes à main nue des blessures. ni laisser des liquides chauds entrer en contact avec la peau.
D Remettre en place les portes, panneaux, recouvrements ou PRESSION D’AIR RÉSIDUELLE dispositifs de protection à la fin des travaux d’entretien et avant ET DES FLEXIBLES QUI FOUETTENT de mettre le moteur en marche. risquent de provoquer des blessures. D Détendre la pression pneumatique des outils et PIÈCES CHAUDES peuvent...
D Demander seulement à des personnes qualifiées familiarisées LES CHARGES ÉLECTROSTATI- avec des équipements électroniques de faire fonctionner l’installa- QUES peuvent endommager les tion. circuits imprimés. D L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces.
2-8. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- from Global Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org). www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, from National Fire Protection Association, and Cutting, American Welding Society Standard AWS F4.1, from Glob-...
SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Fast (Run, Weld/ Stop Engine Slow (Idle) Start Engine Power) Check engine belt Check Air Cleaner Starting Aid Engine Battery (Engine) Hourmeter (HM) Temperature Circuit Protector Do Not Switch Read Operator’s Certified/Trained Engine Oil Under Load Manual...
4-4. Stick And MIG Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all A. DC Stick Mode other settings fall between the curves shown. Ranges 300−M ax 185−525 125−400 85−250...
4-5. DC TIG Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. D CAMPERES 251 479-A 4-6. Fuel Consumption The curve shows typical fuel use under weld or generator power loads.
4-7. Generator AC Power Curve The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. AC AMPERES IN 240V MODE AC AMPERES IN 120V MODE 240 054-A OM-244 023 Page 20...
SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 5-2.
5-3. Mounting Welding Generator Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. Supporting The Unit NOTICE − Do not mount unit by supporting the base only at the four mounting brackets.
5-4. Grounding Generator To Truck Or Trailer Frame Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators.
5-5. Installing Exhaust Pipe Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Tools Needed: 1/2 in. Exhaust1 2008−01 Ref. 803 604 / Ref. 215 664 5-6. Installing Optional Spark Arrestor Muffler Stop engine and let cool.
5-7. Activating The Dry Charge Battery (If Applicable) Always wear a face shield, rubber gloves and protective clothing when working on a battery. Remove battery from unit. Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum).
5-9. Using The Optional Battery Disconnect Switch Stop engine. Battery Disconnect Switch The battery disconnect switch dis- connects battery voltage from the circuit. When the switch is turned Off, the front panel controls do not work. To run unit, turn switch to On posi- tion.
5-10. Engine Prestart Checks Engine Oil Engine stops if fuel level is low. Full Diesel Engine Oil Level Cold High Warm High Cold Low Warm 803 454 / 244 400-A Fuel Cold Weather Starting Check all engine fluids daily. NOTICE − Do not use gasoline. Gasoline To improve cold weather starting: will damage engine.
5-11. Connecting To Weld Output Terminals Stick And TIG Welding MIG And FCAW Welding For Stick welding Direct Current Electrode For MIG welding Direct Current Electrode Positive (DCEP), connect electrode hold- Positive (DCEP), connect wire feeder er cable to Positive (+) terminal on left and cable to Positive (+) terminal on left and work cable to Negative (−) terminal on work cable to Negative (−) terminal on...
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart) Ref. S-0007-G 2009−08 OM-244 023 Page 29...
5-13. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information 24 volts ac. Protected by sup- plementary protector CB5 (see Section 8-9). 24 VOLTS AC Contact closure to A completes 24 volt ac contactor control circuit. Output to remote control:+10 volts dc in MIG or Stick mode;...
5-14. Connections To Terminal Strip T10 Terminal Strip T10 There are two bushings on the aux- iliary power panel through which leads can be routed to T10. YELLOW YELLOW YELLOW BROWN PURPLE BLUE ORANGE PINK BLACK /GREEN /GREEN 24 VAC EQUIPMENT 115 VAC GROUND...
6-2. Description Of Controls (See Section 6-1) Engine Starting Controls if fuel level is low. For most welding applications, use lowest amperage range possible to help prevent arc Starting Aid Switch To check fuel level when engine is not run- outages.
6-3. Process/Contactor Switch Process/Contactor Switch Weld output terminals are ener- gized when Process/Contactor switch is in a Weld Terminals Al- ways On position and the en- gine is running. DC voltage is still present at the weld terminals when Process/ Contactor switch is in the Re- mote On/Off Switch Required −...
6-4. Using Remote Voltage/Amperage Control Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-13). 803 454 In Example: Example: Combination Remote Amperage Control (Stick) Process = Stick (Using Remote On/Off) Range = 125 to 400 A DC Min = 125 A DC Max = 400 A DC Max (400 A DC)
SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Auxiliary Power Receptacles 238 127-A / 805 259-A Circuit Breaker CB1 power at weld/power speed. Maximum combined output of all recep- tacles is 4 kVA/kW. CB1 protects GFCI1 from overload. If a cir- If a ground fault is detected, receptacle Re- EXAMPLE: If 13 A is drawn from RC1, only cuit breaker opens, the receptacle does not...
SECTION 8 − ENGINE/GENERATOR MAINTENANCE 8-1. 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...
8-3. Operating Optional Oil Pan Heater Optional Oil Heater Plug Use heater to maintain a constant engine oil temperature. To turn on heater, connect heater plug to receptacle. Do not run engine while oil pan heater is on. NOTICE −In extremely cold weath- er, heater should be connected to power source when engine oil is warm to eliminate possibility of oil...
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. Engine Air Cleaner The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each cleaning.
8-5. Inspecting/Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhaust pipe with fireproof material.
8-8. Servicing Engine Fuel And Lubrication Systems Tools Needed: 803 454 To drain water from fuel system: To drain sludge from fuel tank: Stop engine and let cool. Open primary fuel filter petcock and drain After servicing, start engine and Beware of fire.
8-9. Engine/Generator Overload Protection Stop engine. When a supplementary protector, circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. Fuse F1 Fuse F2 F1 and F2 protect the stator exciter winding from overload. If F1 opens, weld and generator power is low or stops entirely.
SECTION 9 − TROUBLESHOOTING 9-1. Troubleshooting Tables A. Welding Trouble Remedy No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote okay at ac receptacles. position and connect remote contactor to Remote 14 receptacle RC14 (see Sections 5-13 and 6-1). Check position of Ampere Range switch.
Page 50
Trouble Remedy No remote fine amperage or voltage Place Panel/Remote switch in Remote position. control. Check and secure connections to Remote 14 receptacle RC14 (see Section 5-13). Repair or replace remote control device. Have Factory Authorized Service Agent check PC1 current sensing leads (36 and 37), and connections. Constant speed wire feeder does not Reset supplementary protector(s) CB5 and CB13 (see Section 8-9).
Page 51
Trouble Remedy Engine cranks but does not start. Check fuel level. Optional low fuel shutdown stops engine if fuel level is low. Reset supplementary protector CB13 (see Section 8-9). Have Factory Authorized Service Agent check engine wiring harness and components. Check battery and replace if necessary.
SECTION 11 − RUN-IN PROCEDURE run_in1 2007−04 11-1. Wetstacking NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.
11-2. Run-In Procedure Using Load Bank Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur.
11-3. Run-In Procedure Using Resistance Grid Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur.
SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding 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 58
12-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #8 AWG or larger insulated copper wire. 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 59
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 60
12-7. Approximate Power Requirements For Contractor Equipment Contractor 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 14 in...
Page 61
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 AC MOTOR To find starting amperage: VOLTS AMPS Step 1: Find code and use table to CODE find kVA/HP.
Page 62
12-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Fused Properly install and ground Welding Utility Disconnect this equipment according to Electrical Generator Transfer Switch Switch its Owner’s Manual and na- Output Service (If Required)
Page 63
12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68) 137 (42)
SECTION 13 − PARTS LIST Hardware is common and not available unless listed. 116 − Figure 13-2 122 − Figure 13-3 Figure 13-1. Main Assembly OM-244 023 Page 60...
Page 70
Item Dia. Part Mkgs. Description Quantity Figure 13-2. Control Box Assembly − (Continued) ....206736 Harness, Control Box, Weld Control LH (includes) .
Page 71
Hardware is common and not available unless listed. Ref: 803 457-E Figure 13-3. Panel, Front w/Components Item Dia. Part Mkgs. Description Quantity Figure 13-3. Panel, Front w/Components (Figure 13-1 Item 122) ....239132 Plate, Screened Ident Control (Order By Model And Serial Number) .
Page 72
Item Dia. Part Mkgs. Description Quantity Figure 13-3. Panel, Front w/Components (Continued) ....192558 Harness, Range Switch (includes) ........
Page 73
245 341 Figure 13-4. Auxiliary Power Group, Export Item Dia. Part Mkgs. Description Quantity Figure 13-4. Auxiliary Power Group ....244134 Panel, Aux Power .
Page 74
Hardware is common and not available unless listed. 803 327 Figure 13-5. Generator Item Dia. Part Mkgs. Description Quantity Figure 13-5. Generator (Figure 13-1 Item 98) ....132053 Screw, 375−16x1.50 Hex Hd−pln Gr5 Pld .
Page 77
Effective January 1, 2011 (Equipment with a serial number preface of MB or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...