Miller Big Blue 800 DUO PRO Owner's Manual
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Miller Big Blue 800 DUO PRO Owner's Manual

Engine driven welding generator
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Big Blue 800 DUO PRO
OM-262 752C
Processes
Processes
Description
Engine Driven Welding Generator
)
2014−01
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
File: Engine Drive

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Summary of Contents for Miller Big Blue 800 DUO PRO

  • Page 1 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 Welding Generator Big Blue 800 DUO PRO 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

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 6 − OPERATING WELDING GENERATOR ..........6-1.

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

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2013−09 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 protective clothing when working on a battery.

  • 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_2013−09 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 équipe- LES ACCUMULATIONS DE GAZ ment auxiliaire. Ne pas tester ni réarmer les prises femelles avec risquent de provoquer des blessures différentiel au régime de ralenti/en basse tension: cela endom- magerait le disjoncteur différentiel, qui ne remplirait plus son rôle ou même la mort.

  • 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 D Remettre les portes, panneaux, recouvrements ou dispositifs l’alimentation électrique, verrouiller et étiqueter l’appareil,...
  • Page 16 LA SORTIE DE RECHARGE et L’EXP- LES CHARGES ÉLECTROSTATI- LOSION DE LA BATTERIE peuvent QUES peuvent endommager les provoquer des blessures. circuits imprimés. D Établir la connexion avec la barrette de terre La recharge de batterie n’existe pas sur tous les avant de manipuler des cartes ou des pièces.

  • 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: 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 2012−05 Protect yourself from electric shock by insulating yourself from work and ground.
  • Page 19 Complete Parts List available at www.MillerWelds.com Do not work on unit if engine is running. Stop engine first. Safe21 2012−05 Do not smoke while fueling or if near fuel. Safe22 2012−05 Stop engine before fueling. Safe23 2012−05 Do not fuel a hot engine. Safe24 2012−05 Use lift eye to lift unit and properly installed accessories only, not gas cylinders.
  • Page 20 Complete Parts List available at www.MillerWelds.com 0 - 50 h std During the first 50 hours of operation keep welding load above 200 amperes. Do not weld below 200 amperes of output. Safe54 2012−05 50 h std After the first 50 hours of operation, change the engine oil and filter. Safe55 2012−05 Never use generator inside a home or garage, even if doors and win- dows are open.

  • Page 21: Miscellaneous Symbols And Definitions

    Complete Parts List available at www.MillerWelds.com 3-2. Miscellaneous Symbols And Definitions Fast (Run, Weld/ Stop Engine Slow (Idle) Start Engine Power) Fuel Battery (Engine) Air Cleaner Engine Oil Radiator Spark Arrestor Engine Belt Filter Engine-Driven, Air Temperature Or Protective Earth Three-Phase Engine Engine...

  • Page 22: 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 front. Use rating label to determine input power requirements and/or rated output.

  • Page 23: Duty Cycle And Overheating

    Complete Parts List available at www.MillerWelds.com 4-5. Duty Cycle And Overheating 100% Duty Cycle Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. This unit is rated for welding at 400 amperes continuously in dual operator mode or 800 am- peres continuously in single operator mode.

  • Page 24: Volt-Ampere Curves

    Complete Parts List available at www.MillerWelds.com 4-7. Volt-Ampere Curves The volt-ampere curves show the A. Stick Mode minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. Parallel Mode Dual Operator DC AMPERES B.

  • Page 25: Ac Generator Power Curves

    Complete Parts List available at www.MillerWelds.com 4-8. AC Generator Power Curves The AC power curve shows the generator power in amperes. A. Single Phase 4 kW 2 8 0 2 6 0 2 4 0 2 2 0 2 0 0 1 8 0 AC AMPERES B.

  • Page 26: Section 5 − Installation

    Complete Parts List available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Installing Welding 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 27: 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 2012−03 − 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 shock and static electricity hazards.

  • Page 28: Connecting The Battery

    Complete Parts List available at www.MillerWelds.com 5-4. Connecting The Battery − Tools Needed: 1/2 in. Conn_batt1 2008−02 802 168-E / Ref. 202 705 / 802 313 / S-0756-C Do not allow the battery cables to Never disconnect the battery while Connect negative (−) cable last.

  • Page 29: Engine Prestart Checks

    Diesel Full 907 561−06 / 907 561−07 / 255 549 / 260 284 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 30: Connecting To Weld Output Terminals

    Complete Parts List available at www.MillerWelds.com 5-6. Connecting To Weld Output Terminals Stop engine. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your ma- Tools Needed: chine. 3/4 in. Do not place anything between weld cable terminal and copper bar.

  • Page 31: Making Dual Operator Cc Weld Connections W/ Separate Work Cables

    Complete Parts List available at www.MillerWelds.com 5-7. Making Dual Operator CC Weld Connections w/ Separate Work Cables Tools Needed: 3/4 in. Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side 258 836 Electrode Holder Cables For Stick/TIG Direct Current Electrode Stop engine.

  • Page 32: Making Dual Operator Mode Cc Weld Connections W/ Common Work Cable

    Complete Parts List available at www.MillerWelds.com 5-8. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable Tools Needed: 3/4 in. Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side 258 836 work cable must be able to carry combined other end of work jumper cable to Welder A Stop engine.

  • Page 33: Making Dual Operator Cv Weld Connections W/ Separate Work Cables

    Complete Parts List available at www.MillerWelds.com 5-9. Making Dual Operator CV Weld Connections w/ Separate Work Cables Tools Needed: 3/4 in. Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side 258 836 Wire Feeder Cables For MIG and FCAW Direct Current Elec- Stop engine.

  • Page 34: Making Dual Operator Cv Weld Connections W/ Common Work Cable

    Complete Parts List available at www.MillerWelds.com 5-10. Making Dual Operator CV Weld Connections w/ Common Work Cable Tools Needed: 3/4 in. Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side 258 836 weld output of both modules (see Section mon work cable and work jumper cable to Stop engine.

  • Page 35: Making Dual Operator Cc And Cv Weld Connections W/ Separate Work Cables

    Complete Parts List available at www.MillerWelds.com 5-11. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables Tools Needed: 3/4 in. Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side 258 836 For Stick/TIG welding Direct Current Elec- For MIG and FCAW welding Direct Current Stop engine.

  • Page 36: Making Dual Operator Cc And Cv Weld Connections W/ Common Work Cable

    Complete Parts List available at www.MillerWelds.com 5-12. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable Tools Needed: 3/4 in. Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side Ref. 251 340-A / Ref. 802 292-A 5-14 for proper cable size).

  • Page 37: Making Single Operator Cc Weld Connections

    Complete Parts List available at www.MillerWelds.com 5-13. Making Single Operator CC Weld Connections Direct Current Electrode Positive (DCEP) connections are shown. Welder B (right) Terminals Inactive In Single Operator Mode Welder A (Left) Side Tools Needed: 3/4 in. 258 836 For Stick/TIG welding Direct Current Elec- Stop engine.

  • Page 38: Weld Output Terminals And Selecting Cable Sizes

    **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-K 2013−09 OM-262 752 Page 34...

  • Page 39: Connecting To Remote 14 Receptacle

    Complete Parts List available at www.MillerWelds.com 5-15. Connecting To Remote 14 Receptacle *The remaining sockets Socket* Socket Information are not used. Not all models have contactor control. See description of front panel controls and circuit diagram. 24 volts AC. Protected by supplementary protector. 24 VOLTS AC Contact closure to A completes 24 volt AC contactor control circuit.

  • Page 40: Section 6 − Operating Welding Generator

    Complete Parts List available at www.MillerWelds.com SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls (See Section 6-2) 262 528 / 907 587−1 OM-262 752 Page 36...

  • Page 41: Description Of Front Panel Controls (See Section 6-1)

    Voltage/Am- plays weld voltage and then defaults to preset perage control adjusts voltage and amper- voltage. NOTICE − Diesel engines in MILLER equip- age. ment are meant to operate optimally at mod- Weld Controls erate to rated load. Using light or no load for...

  • Page 42: Process/Contactor Switch

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

  • Page 43: Arc Control

    Complete Parts List available at www.MillerWelds.com 6-5. Arc Control Arc Control Stick Control adjusts Dig when Stick is se- lected on mode switch. When control is set toward minimum, short-circuit amperage at low arc voltage is the same as normal weld- ing amperage.

  • Page 44: Low Open-Circuit Voltage (Vrd) Switch Mode

    Complete Parts List available at www.MillerWelds.com 6-6. Low Open-Circuit Voltage (VRD) Switch Mode Voltage Reducing Device (VRD) Switch The VRD switch can be set for low open-circuit voltage operation in Stick mode. When the unit is con- figured for low open-circuit voltage operation only a low sensing voltage (approximately 15 volts DC) is present between the elec-...

  • Page 45: Lift-Arct Tig With Auto-Stopt

    Complete Parts List available at www.MillerWelds.com 6-8. Lift-Arct TIG With Auto-Stopt Arc Start With Lift-Arc TIG Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted. Arc Start With Lift-Arc Select Lift-Arc TIG at Process/ Contactor switch.

  • Page 46: Remote Voltage/Amperage Control

    Complete Parts List available at www.MillerWelds.com 6-9. Remote Voltage/Amperage Control Remote 14 Receptacle Connect optional remote control to receptacle (see Section 5-15). When a remote control is connected to the Remote receptacle, the Auto Sense Re- mote feature automatically switches volt- age/amperage control to the remote con- trol.

  • Page 47: Engine Block Heater Operation

    Complete Parts List available at www.MillerWelds.com 6-10. Engine Block Heater Operation Engine Block Heater Plug Use heater to maintain a constant engine coolant temperature. To turn on heater, connect heater Heater Specifications plug to 120 volts AC receptacle. Do not run engine while en- ±...

  • Page 48: Section 7 − Operating Auxiliary Equipment

    Complete Parts List available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Auxiliary Power Receptacles 251 249-A / 248 894-A 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 49: Gfci Receptacle Information, Resetting And Testing

    Complete Parts List available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting And Testing Test and reset GFCI only at Run speed. RotGFCI1 2012−05 If a ground fault is detected, the GFCI Reset Check for damaged or wet tools, cords, Use GFCI protection when operat- button pops out, and the circuit opens to plugs, etc.

  • Page 50: Section 8 − Maintenance

    Complete Parts List available at www.MillerWelds.com SECTION 8 − 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...

  • Page 51: Checking Generator Brushes

    Complete Parts List available at www.MillerWelds.com 8-2. Checking Generator Brushes Stop engine and let cool. Generator Brush Mark and disconnect leads at brush hold- 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 52: Servicing Air Cleaner

    Complete Parts List available at www.MillerWelds.com 8-4. Servicing Air Cleaner Stop engine. Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element 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 cleaning.

  • Page 53: Engine Speed Adjustment

    Complete Parts List available at www.MillerWelds.com 8-5. Engine Speed Adjustment Engine functions are controlled by the engine ECU. Tampering with the engine ECU will void engine warranty. Contact engine Factory Authorized Service Agent for engine adjustments. 8-6. Oil Specifications Synthetic Oil Viscosity Chart For any normal oil change interval, any en- gine oil with a CJ-4 and low ash rating may be used.

  • Page 54: Servicing Fuel And Lubrication Systems

    Complete Parts List available at www.MillerWelds.com 8-7. Servicing Fuel And Lubrication Systems Tools Needed: 907 587−2 formation. on the Engine Display, see Sections 12-12 Stop engine and let cool. and 12-13. To replace fuel filters: After servicing, start engine and To drain sludge from fuel tank: check for fuel leaks.

  • Page 55: Engine/Generator Overload Protection

    Complete Parts List available at www.MillerWelds.com 8-8. Engine/Generator Overload Protection 907 587−2 / 803 229 opens, weld output is low or stops entirely. Supplementary Protector CB12 Stop engine. 4 kVA/kW generator power is still available. CB12 protects the fuel pump circuit. If When a supplementary protector, cir- CB12 opens, the fuel pump does not work Supplementary Protector CB3...

  • Page 56: Voltmeter/Ammeter Help Displays

    Complete Parts List available at www.MillerWelds.com 8-9. Voltmeter/Ammeter Help Displays HL.P HL.P HL.P HL.P HL.P Use the Voltmeter/Ammeter help displays shown, have Factory Authorized Service ping and restarting the unit or by turning to diagnose and correct fault conditions. Agent check TH1, and the wiring between Process/Contactor switch to another posi- TH1 and PC1.

  • Page 57: Section 9 − Troubleshooting

    Complete Parts List available at www.MillerWelds.com SECTION 9 − TROUBLESHOOTING 9-1. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-9). Also see Engine Information Display to assist in troubleshooting engine related problems (see Section 12). A.
  • Page 58 Complete Parts List available at www.MillerWelds.com Trouble Remedy Constant speed wire feeder does not Reset supplementary protector CB9 (see Section 8-8). work. Check and secure connections to Remote 14 receptacle (see Section 5-15). Repair or replace wire feeder. Low CV weld output. Increase Voltage/Amperage Adjust Control setting.

  • Page 59: Section 10 − Parts List

    Complete Parts List available at www.MillerWelds.com Trouble Remedy Have Factory Authorized Service Agent check control relay CR5 and Engine Control switch S1. Engine cranks but does not start. Check fuel level. Check battery and replace if necessary. Check engine charging system according to engine manual. Have Factory Authorized Service Agent check control relay CR5.

  • Page 60: Section 11 − Electrical Diagrams

    SECTION 11 − ELECTRICAL DIAGRAMS Figure 11-1. Circuit Diagram For Welding Generator − Part 1 OM-262 752 Page 56...
  • Page 61 262 749-B OM-262 752 Page 57...
  • Page 62 Figure 11-2. Circuit Diagram For Welding Generator − Part 2 OM-262 752 Page 58...
  • Page 63 262 749--B OM-262 752 Page 59...

  • Page 64: Section 12 − Engine Information Display

    SECTION 12 − 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. 12-1. Display Layout And Controls Engine Information Display Engine Control Switch Function Buttons Yellow LED Red LED The Engine Information Display...
  • Page 65 12-3. 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 5 minutes or longer, the RPM signal failed message ap- pears.
  • Page 66 12-5. 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 67: Fuel Level

    12-7. 1-Up Displays 1-Up Machine Hours 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. Machine Hours 15 18 Battery Potential Coolant Temperature...
  • Page 68 12-8. 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 69 12-9. 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 12-10 and 12-11). 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 70 12-10. 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. Fault Shutdown Indicator 45 60 The shutdown symbol appears on the display when a severe engine fault can cause shutdown.
  • Page 71 Table 12-1. 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 Low fuel pressure; warning threshold exceeded Low oil pressure; warning threshold exceeded High coolant temperature;...
  • Page 72 12-12. 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 73 12-14. 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 74 12-15. 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 75 12-16. 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 76: Section 13 − Run-In Procedure

    2013−10 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 77: Run-In Procedure Using Load Bank Or Resistance Grid

    13-2. Run-In Procedure Using Load Bank Or Resistance Grid S-0683 / S-0684 Stop engine. Connect load bank or resistor grid to For Resistance Grid generator Side A weld output terminals Set grid switches and then adjust gen- Do not touch hot exhaust pipe, en- using proper size weld cables with correct erator A/V control so load equals rated gine parts, or load bank/grid.

  • Page 78: Section 14 − Generator Power Guidelines

    SECTION 14 − 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. 14-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...

  • Page 79: Grounding When Supplying Building Systems

    14-3. 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 80 14-5. 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 81 14-7. 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 82 14-8. 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 83 14-10. 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 to its Owner’s Manu- Fused Welding Utility al and national, state, and lo- Disconnect Generator Electrical...
  • Page 84 14-11. 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 (AWG)* Current Load (Watts)
  • Page 85 Notes OM-262 752 Page 81...
  • Page 86 Notes OM-262 752 Page 82...
  • Page 87 Effective January 1, 2014 (Equipment with a serial number preface of ME 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 88 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 2014 Miller Electric Mfg. Co. 2014−01...

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