Miller Big Blue 500 Pro Owner's Manual
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Miller Big Blue 500 Pro Owner's Manual

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OM-290968C
2022-11
Processes
Multiprocess Welding
Description
Engine Driven Welder/Generator
Big Blue
500 Pro And
®
Big Blue
600 Pro
®
Deutz
OWNER'S MANUAL
For product information,
Owner's Manual translations,
and more, visit
www.MillerWelds.com

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Do you have a question about the Big Blue 500 Pro and is the answer not in the manual?

Questions and answers

Jonathan
April 7, 2025

Does not weld but generator works

0
1 comments:
Mr. Anderson
April 7, 2025

If the Miller Big Blue 500 Pro does not weld but the generator works, possible reasons include:

1. The Process/Contactor switch is not in an Electrode Hot or Remote On/Off position.
2. The remote contactor is not connected to the Remote receptacle if required.
3. Supplementary protectors CB3 or CB9 are open and need to be reset.
4. There is a faulty remote device connected to the Remote receptacle.
5. The connections to the Remote receptacle are loose or faulty.
6. Fuse F2 is open and needs replacement.
7. There may be issues with the brushes, slip rings, weld excitation circuit, or rotor, which require inspection by a Factory Authorized Service Agent.

This answer is automatically generated

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Summary of Contents for Miller Big Blue 500 Pro

  • Page 1 OM-290968C 2022-11 Processes Multiprocess Welding Description Engine Driven Welder/Generator Big Blue 500 Pro And ® Big Blue 600 Pro ® Deutz OWNER’S MANUAL 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 Symbol Usage .
  • Page 4 TABLE OF CONTENTS SECTION 8 – MAINTENANCE AND TROUBLESHOOTING ..............48 Maintenance Label .

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

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING 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 not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 Accidental contact of electrode to metal objects can cause sparks, ex- FLYING METAL OR DIRT can injure plosion, overheating, or fire. Check and be sure the area is safe be- eyes. fore doing any welding. � Welding, chipping, wire brushing, and grinding �...

  • Page 7: Engine Hazards

    � Install cylinders in an upright position by securing to a stationary � Turn face away from valve outlet when opening cylinder valve. Do support or cylinder rack to prevent falling or tipping. not stand in front of or behind the regulator when opening the valve.

  • Page 8: Compressed Air Hazards

    1-4. Compressed Air Hazards � Reinstall doors, panels, covers, or guards when servicing is fin- COMPRESSED AIR EQUIPMENT can ished and before starting unit. injure or kill. � If ANY air is injected into the skin or body seek medical help immediately.
  • Page 9 � Follow the guidelines in the Applications Manual for the Revised HIGH PRESSURE FLUIDS can injure NIOSH Lifting Equation (Publication No. 94-110) when manually or kill. lifting heavy parts or equipment. � Engine fuel system components can be under high OVERHEATING can damage motors.

  • Page 10: California Proposition 65 Warnings

    � If notified by the FCC about interference, stop using the equipment � Be sure all equipment in the welding area is electromagnetically at once. compatible. � Have the installation regularly checked and maintained. � To reduce possible interference, keep weld cables as short as �...

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

    SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION 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 � Ne pas toucher aux portes-électrodes qui sont raccordés à deux bien ventilé, et en portant un respirateur à alimentation d’air. Les machines à souder en même temps, car cela entraîne la présence revêtements et tous les métaux renfermant ces éléments peuvent d’une tension de circuit-ouvert double.

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    � Ne pas souder là où l’air ambiant pourrait contenir des poussières, � Les porteurs d’implants médicaux doivent consulter leur médecin gaz ou émanations inflammables (vapeur d’essence, par et le fabricant du dispositif avant de s’approcher de la zone où se exemple).

  • Page 14: Dangers Liés À L'air Comprimé

    � Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces � Ne pas toucher aux pièces chaudes, utiliser les outils recomman- inflammables. dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. � Tenir à distance les produits inflammables de l’échappement. LA VAPEUR ET LE LIQUIDE DE Les PIÈCES MOBILES peuvent REFROIDISSEMENT CHAUD peuvent...

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

    L’AIR COMPRIMÉ risque de Les PIÈCES MOBILES peuvent provoquer des blessures ou même la causer des blessures. mort. � S’abstenir de toucher des parties mobiles telles � Avant d’intervenir sur le circuit d’air comprimé, que des ventilateurs, courroies et rotors. couper l’alimentation électrique, verrouiller etéti- �...
  • Page 16 � Utiliser uniquement des équipements adéquats pour un fonction- � Régler les commandes de charge de batterie sur la position d’arrêt nement avec une alimentation de 50/60 ou de 60 Hz. avant de brancher la batterie. Veiller à ce que les pinces de charge ne se touchent pas.

  • Page 17: Proposition Californienne 65 Avertissements

    � Effectuer l’installation, l’entretien et toute intervention selon les LE SOUDAGE À L’ARC risque de manuels d’utilisateurs, les normes nationales, provinciales et de provoquer des interférences. l’industrie, ainsi que les codes municipaux. � L’énergie électromagnétique risque de provoquer LE RAYONNEMENT HAUTE des interférences pour l’équipement électronique FRÉQUENCE (H.F.) risque de sensible tel que les ordinateurs et l’équipement...
  • Page 18 les porteurs d’implants médicaux doivent être prises: par exemple, 5. Connecter la pince sur la pièce aussi près que possible de la des restrictions d’accès pour les passants ou une évaluation indivi- soudure. duelle des risques pour les soudeurs. Tous les soudeurs doivent ap- 6.

  • Page 19: Section 3 - Definitions

    Some symbols are found only on CE products. facility. Some symbols are found only on CE products. Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Contact your local recycling office or your local distributor for further information. Safe �...
  • Page 20 Turn off power before disassembling torch. � Complete Parts List is available at www.MillerWelds.com Safe19 201 Do not remove or paint over (cover) the label. Do not remove or paint over (cover) the label. Safe20 201 Do not work on unit if engine is running. Stop engine first. Do not work on unit if engine is running.
  • Page 21 Become trained and read the instructions and labels before working on machine. Hot muffler and exhaust pipe can cause severe burns. � Complete Parts List is available at www.MillerWelds.com Safe9 Safe35 2012 05 Hazardous voltage remains on input capacitors after power is turned Hazardous voltage remains on input capacitors after power is turned off.

  • Page 22: Miscellaneous Symbols And Definitions

    Connect green or green/yellow grounding conductor to ground Connect green or green/yellow grounding conductor to ground terminal. terminal. Connect input conductors (L1, L2 And L3) to line terminals. Connect input conductors (L1, L2 And L3) to line terminals. � Complete Parts List is available at www.MillerWelds.com Safe86 2012 06 Safe86 2012 06 Never use generator inside a home or garage, even if doors and win-...
  • Page 23 ositive Engine Gas (TIG) Rectifier Welding Welding Flux Cored Arc Positive Engine Circuit Breaker 1/2 in. Welding (FCAW) Air Cleaner Flux Cored Arc (13 mm) ernating Supplementary � Flux Cored Arc Engine Stop Complete Parts List is available at www.MillerWelds.com Welding (FCAW) rent (AC) Protector...

  • Page 24: Section 4 - Specifications

    Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...

  • Page 25: Environmental Specifications

    This unit is rated for welding at 500 am- peres continuously. NOTICE – Exceeding duty cycle can dam- age unit and void warranty. Big Blue 600 Pro Models 1000 % DUTY CYCLE 272798B Big Blue 500 Pro Models 1000 277791-A % DUTY CYCLE 275897-A OM-290968 Page 21...

  • Page 26: Fuel Consumption

    � Complete Parts List is available at www.MillerWelds.com 1-3. Fuel Consumption 4-8. Fuel Consumption The curve shows typical fuel use under weld 2.50 or power loads. 2.25 2.00 1.75 1.50 1.25 1.00 0.75 0.50 IDLE 0.25 0.00 DC WELD AMPERES AT 100% DUTY CYCLE 272795-B OM-278739 Page 10 OM-290968 Page 22...

  • Page 27: Volt-Ampere Curves (Big Blue 500 Models)

    1-5. Volt-Ampere Curves (Big Blue 500 Models) � Complete Parts List is available at www.MillerWelds.com 1-5. Volt-Ampere Curves (Big Blue 500 Models) 1-5. Volt-Ampere Curves (Big Blue 500 Models) 4-9. Volt-Ampere Curves (Big Blue 500 Models) Stick Mode The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welder/generator.

  • Page 28: Volt-Ampere Curves (Big Blue 600 Models)

    � Complete Parts List is available at www.MillerWelds.com 4-10. Volt-Ampere Curves (Big Blue 600 Models) 1-4. Volt-Ampere Curves (Big Blue 600 Models) 1-4. Volt-Ampere Curves (Big Blue 600 Models) Stick Mode The volt-ampere curve shows the minimum 1-4. Volt-Ampere Curves (Big Blue 600 Models) and maximum voltage and amperage output capabilities of the welder/generator.

  • Page 29: Generator Power Curves

    � Complete Parts List is available at www.MillerWelds.com 4-11. Generator Power Curves The AC power curves show the generator Single Phase 4 kW power in amperes. AC Amperes AC Amperes AC Amperes Three Phase 20 kW AC Amperes AC Amperes AC Amperes Single Phase 12 kW AC Amperes...

  • Page 30: Section 5 - Installation

    � Complete Parts List is available at www.MillerWelds.com SECTION 5 – INSTALLATION 5-1. Installing Welder/Generator Movement And Airflow Clearance 18 in. 18 in. (460 mm) (460 mm) 18 in. 18 in. (460 mm) 18 in. 18 in. (460 mm) (460 mm) (460 mm) 18 in.

  • Page 31: Grounding Generator To Truck Or Trailer Frame

    � Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator to Truck or Trailer Frame 1-1. Grounding Generator To Truck Or Trailer Frame GND/PE Bed liners, shipping skids, and 1 Equipment Grounding Terminal Always ground generator frame to some running gear insulate the Front Panel) vehicle frame to prevent electric welding generator from the vehicle...

  • Page 32: Connecting The Battery

    � Complete Parts List is available at www.MillerWelds.com 5-4. Connecting The Battery 907736 / Ref. 907561 01 2-1. Connecting The Battery 1/2 in. Battery is most easily accessed through the � Never start the engine when the cables NOTICE – Lead acid batteries discharge ps head wrench crescent wrench...

  • Page 33: Engine Prestart Checks

    Avoid these issues by considering the following recommendations: � Weather Protection. Use a Miller Cold Weather Kit (Miller part no. 301482). Additional measures may be taken to shield the unit from the elements such as using wind barriers to reduce air flow.

  • Page 34: Weld Output Terminals

    � Complete Parts List is available at www.MillerWelds.com 5-6. Weld Output Terminals 907736 3/4 in. For Stick and TIG Direct Current Electrode cable to Negative (-) terminal on right. Use Stop engine. ps head wrench crescent wrench Negative (DCEN), connect electrode holder Process/Contactor switch to select type of Turn off power before connecting to cable to Negative (-) terminal on right and...

  • Page 35: Connecting To Remote Receptacle

    � Complete Parts List is available at www.MillerWelds.com Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 350 ft 400 ft 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) (105 m) (120 m)

  • Page 36: Section 6 - Operation

    � Complete Parts List is available at www.MillerWelds.com SECTION 6 – OPERATION 6-1. Front Panel Controls (See Section 6-2) OM-290968 Page 32...

  • Page 37: Description Of Front Panel Controls (See Section )

    8 Arc Control Meter GMAW process, turn Adjust control to adjust applied. preset voltage. NOTICE – Diesel engines in Miller equip- Displays current Arc Control setting. Default ment are meant to operate optimally at mod- Select Button value for all processes is 0. Arc Control set- erate to rated load.

  • Page 38: Engine Starting Sequence

    � Complete Parts List is available at www.MillerWelds.com 6-3. Engine Starting Sequence NOTICE – Do not use ether or other starting The Wait to Start display appears when the sequence. Once this message clears, the fluids. Using starting fluids voids warranty. Engine Control switch is placed in the Run engine can be started.

  • Page 39: Process/Contactor Switch

    � Complete Parts List is available at www.MillerWelds.com 6-4. Process/Contactor Switch 1 Process/Contactor Switch Weld output terminals are energized when Process/Contactor switch is in an Electrode Hot position and the en- gine is running. Use switch to select weld process and weld output on/off control (see table below).

  • Page 40: Service Menu

    � Complete Parts List is available at www.MillerWelds.com 6-5. Service Menu 1 Adjust Control/Select Button Press and hold control for 5 seconds, then re- lease to access the Service Menu. Rotate the knob to scroll through the menu items. Press and release the control to access the options and information within each menu item.

  • Page 41: Arc Control Settings

    � Complete Parts List is available at www.MillerWelds.com 6-6. Arc Control Settings � Arc Control is not active when the Process/Contactor switch is in the following positions: Output On Remote ON/OFF: GTAW (Remote TIG) Complete Parts List is available Process/Contactor Switch Arc Control Complete Parts List is available GMAW/FCAW...

  • Page 42: Dynamic Dig Settings

    Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it. � Miller recommends Hobart filler metals. OM-290968 Page 38...

  • Page 43: Lift-Arc™ Tig With Auto-Stop™ And Auto-Crater

    Remote control is not needed when us- ing Auto-Crater. 1. While welding. 2. Lift torch slightly to start Auto-Crater end (current is reduced). 3. Lower torch. Weld current ramps down. 4. Shielding gas continues until shut off. � Miller recommends Hobart filler metals. OM-290968 Page 39...

  • Page 44: Remote Voltage/Amperage Control

    � Complete Parts List is available at www.MillerWelds.com 6-10. Remote Voltage/Amperage Control Complete Parts List available at www.MillerWelds.com 1-1. Voltage/Amperage Control With 14-Pin Remote Accessory Remote Receptacle Connect optional remote control to 1 Remote Receptacle receptacle. Connect optional remote control to recep- When a remote control is con- Big Blue 800 Duo Air Pak shown.

  • Page 45: Operating Engine Block Heater

    � Complete Parts List is available at www.MillerWelds.com 6-11. Operating Engine Block Heater 1 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. Do not run engine while engine block heater is on.

  • Page 46: Updating Software

    � Complete Parts List is available at www.MillerWelds.com 6-12. Updating Software Preparing For Software Update Step 1. Verify the current software version installed. Press and hold the Adjust Control/Select button for 5 seconds, then release to access the Service Menu. Step 2.

  • Page 47: Summary File

    � Complete Parts List is available at www.MillerWelds.com 2-5. Summary File 6-13. Summary File 1 Summary File Each time a USB stick is inserted in the USB receptacle, a summary file is saved to the USB stick as SummaryFile.txt. "USB ACC" will display as the file is written. File is complete when display no longer shows "USB ACC."...

  • Page 48: Fuel/Hour Gauge Descriptions

    � Complete Parts List is available at www.MillerWelds.com 11-25. Fuel/Hour Gauge Descriptions 6-14. Fuel/Hour Gauge Descriptions OM-290968 Page 44...

  • Page 49: Associating Arcreach

    � Complete Parts List is available at www.MillerWelds.com 6-15. 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 50: Section 7 - Operating Auxiliary Equipment

    � Complete Parts List is available at www.MillerWelds.com SECTION 7 – OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles 271858-B RC1, RC2, GFCI1 and GFCI2 do not work. RC5 is connected to the three-phase gener- Single-Phase Generator Power Place switch in On position to reset. ator and supplies 60 Hz single-phase power Use GFCI protection when operating at weld/power speed.

  • Page 51: Gfci Receptacle Information, Resetting, And Testing

    � Complete Parts List is available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting, And Testing Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles auxiliary equipment. If unit does not button pops out, and the circuit opens to dis- If a GFCI fault occurs, stop engine and dis- have GFCI receptacles, use GFCI- connect power to the faulty equipment.

  • Page 52: Section 8 - Maintenance And Troubleshooting

    � Complete Parts List is available at www.MillerWelds.com SECTION 8 – MAINTENANCE AND TROUBLESHOOTING 8-1. Maintenance Label 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 53: Routine Maintenance

    Hours Manual, e engine, and the engine will not start or Sections When servicing a Miller gasoline-powered welder/generator, always perform the following basic 5-5, 8-4 oo high. Symptom: Fuel will plug the fuel engine checks before contacting the engine manufacturer.

  • Page 54: Servicing Air Cleaner

    � Complete Parts List is available at www.MillerWelds.com *To be done by factory authorized service agent. NOTE: This standard is now used for IED/PED models with plastic air cleaner housing. 8-4. Servicing Air Cleaner Stop engine. NOTICE – Do not run engine without air cleaner or with dirty element.

  • Page 55: Checking Generator Brushes

    � Complete Parts List is available at www.MillerWelds.com 8-5. Checking Generator Brushes FUEL WATER Stop engine and let cool. 1 Generator Brush 2 Minimum Length: 5/8 in. (16 mm) 3 New Length: 1–1/4 in. (32 mm) 4 Damaged Brush Mark and disconnect leads at brushholder cap.

  • Page 56: Battery Maintenance

    � Complete Parts List is 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 57: Servicing Fuel And Lubrication Systems

    � Complete Parts List is available at www.MillerWelds.com 8-10. Servicing Fuel And Lubrication Systems tools/ Stop engine and let cool. Turn filter counterclockwise. Remove filter. Once the air has escaped, fuel will begin to flathead philips head wrench crescent wrench seep out of the spout and from underneath After servicing, start engine and For primary fuel filter, transfer water sensor...

  • Page 58: Draining Fuel Water Separator (Primary Fuel Filter)

    � Complete Parts List is available at www.MillerWelds.com 8-11. Draining Fuel Water Separator (Primary Fuel Filter) Draining the fuel water separator (primary fuel filter) The fuel water separator sensor will shut down the engine when it has accumulated approximately 8oz. of water. Drain the separator as de- scribed below.

  • Page 59: Engine/Generator Overload Protection

    � Complete Parts List is available at www.MillerWelds.com 8-12. Engine/Generator Overload Protection 907834 Stop engine. CB3 protects the engine weld control circuit. CB12 protects the fuel pump circuit. If CB12 If CB3 opens, weld output stops, meters will opens, the fuel pump does not work and the be blank;...

  • Page 60: Voltmeter/Ammeter Error Displays

    � Complete Parts List is available at www.MillerWelds.com 8-13. Voltmeter/Ammeter Error Displays 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. �...
  • Page 61 � Complete Parts List is available at www.MillerWelds.com Trouble Remedy Erratic weld output. Check and tighten connections inside and outside unit. Be sure connection to work piece is clean and tight. Use dry, properly stored electrodes. Remove excessive coils from weld cables. Have Factory Authorized Service Agent check brushes and slip rings.
  • Page 62 � Complete Parts List is available at www.MillerWelds.com D. Engine Trouble Remedy Engine will not crank. Supplementary protector CB2 open. Reset CB2. Check fuel level. Check battery connections and tighten if necessary. Check battery, and replace if necessary. Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8- 12).

  • Page 63: Section 9 - Parts List

    � Complete Parts List is available at www.MillerWelds.com SECTION 9 – PARTS LIST 9-1. Recommended Spare Parts Item No. Dia. Mkgs. Part No. Description Quantity 284184 USB Flash Drive F1, F2 085874 Fuse, Mintr Cer Slo-blo 10. Amp 250 Volt See Maintenance Label For Engine Replacement Parts Battery, Stor 12V 925 Crk 195 Rsv Gp 31 Maint Free To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts.

  • Page 64: Section 10 - Electrical Diagrams

    SECTION 10 – ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welder/Generator (Page 1 of 2) OM-290968 Page 60...
  • Page 65 290931-B OM-290968 Page 61...
  • Page 66 290930-B Figure 10-2. Circuit Diagram For Welder/Generator (Page 2 of 2) OM-290968 Page 62...

  • Page 67: 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 1 Engine Information Display 2 Engine Control Switch 3 Function Buttons The Engine Information Display turns on whenever the Engine Control switch is in ei-...
  • Page 68 11-3. RPM Signal Failed Display 1 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 condition exists for 30 minutes or longer, the RPM signal failed message appears.
  • Page 69 11-4. Displays To go to the next display, press the Next function button twice. To return to previous display, press the Previous function button twice. OM-290968 Page 65...
  • Page 70 11-5. Fuel Level Warnings � Fuel level warnings are generated by sensors at the fuel tank. All engine warnings that are displayed are gener- ated by the engine controller (see Sec- tion 11-6). 1 Low Fuel Warning The low fuel warning indicator appears and begins to flash when fuel level reaches 15%.
  • Page 71 11-6. Warning Or Shutdown Display 1 Oil Pressure Shutdown Display Showdown information is displayed on the screen after the fault. The SPN and FMI numbers are generated by the engine controller according to the J1939 standard. Typical faults are listed in Table 11–1.
  • Page 72 11-7. Main Menu Access 1 Password Display A password is required to gain access to the main menu. This display appears whenever the Menu button is pressed. 2 Operator Password The factory set password is 1100. This ac- cess code cannot be changed. Use keys to enter the password.
  • Page 73 11-8. Main Menu Options 1 Main Menu Menu Structure: � Advanced Settings (Used For Service) Use buttons to move cursor. � Display Settings – Display Source Address – ECU Source Address 2 Select Function Button – Fault Popup – ECU Enable Delay –...

  • Page 74: Section 12 - Run-In Procedure

    SECTION 12 – RUN-IN PROCEDURE NOTICE – Diesel engines in Miller equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended peri- ods 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 Stop engine. 3 Weld Cables Set grid switches and then adjust gener- ator A/V control so load equals rated 4 Resistance Grid Do not touch hot exhaust pipe, en- voltage and current of the generator (see 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 1 Generator Power Receptacles – Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated...
  • Page 77 13-3. Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable GND/PE Use #8 AWG or larger insulated copper wire. 3 Ground Device � Use ground device as stated in electri- cal codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wir- ing 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 Farm/Home Equipment Rating Starting Watts Running Watts Refrigerator or Freezer 3100 Shallow Well Pump 1/3 HP 2150 1/2 HP 3100 1000 Sump Pump 1/3 HP 2100 1/2 HP 3200 1050 13-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment Rating Starting Watts Running Watts Hand Drill...
  • Page 80 13-8. Power Required To Start Motor 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage AC MOTOR VOLTS AMPS Step 1: Find code and use table to find kVA/ CODE HP. If code is not listed, multiply running am- PHASE perage by six to find starting amperage.
  • Page 81 13-10. Typical Connections To Standby Power 1. Utility Electrical 2. Transfer Switch 3. Fused Disconnect 4. Welder/Generator Service Switch (If Required) Output 5. Essential Loads Have only qualified persons perform 1 Utility Electrical Service 4 Welder/Generator Output these connections according to all 2 Transfer Switch (Double-Throw) Generator output voltage and wiring must applicable...
  • Page 82 13-11. Selecting Extension Cord (Use Shortest Cord Possible) A. Cord Lengths For 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension 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 (Amperes)
  • Page 83 Effective January 1, 2022 (Equipment with a serial number preface of NC or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. � Field Options (NOTE: Field options are cov-...
  • Page 84 Appleton, WI 54914 USA tact your distributor and/or equipment manu- facturer’s Transportation Department. International Headquarters–USA USA Phone: 920-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2022-11...

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