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Big Blue 800 DUO PRO
Miller Big Blue 800 DUO PRO User Manual
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Processes
OM-279640B
2017
−
10
Big
Blue
600
Air
Pak
Big
Blue
800
Duo
Pro
Big
Blue
800
Duo
Air
Pak
Processes
Description
TIG (GT
A
W) W
elding
Stick (SMAW
)
W
elding
Engine Driven Welder/Generator And
Air Compressor
Air Carbon Arc (CAC-A)
Cutting and Gouging
MIG (GMAW)
W
elding
Flux Cored (FCA
W
) W
elding
)
)
File:
Engine Drive
For product information,
Owner’
s
Manual translations,
and more, visit
www.MillerWelds.com
)
)
)
)
2
Table of Contents
Table of Contents
3
Section 1 − Safety Precautions − Read before Using
5
Symbol Usage
5
Arc Welding Hazards
5
Engine Hazards
7
Compressed Air Hazards
7
Additional Symbols for Installation, Operation, and Maintenance
8
California Proposition 65 Warnings
10
Principal Safety Standards
10
EMF Information
10
Section 2 − Consignes de Sécurité − Lire Avant Utilisation
11
Signification des Symboles
11
Dangers Relatifs au Soudage à L'arc
11
Dangers Existant en Relation Avec le Moteur
13
Dangers Liés à L'air Comprimé
14
Dangers Supplémentaires en Relation Avec L'installation, le Fonctionnement et la Maintenance
15
Proposition Californienne 65 Avertissements
17
Principales Normes de Sécurité
17
Informations Relatives aux CEM
17
Section 3 − Definitions
19
Additional Safety Symbols and Definitions
19
Miscellaneous Symbols and Definitions
21
Section 4 − Specifications
23
Serial Number and Rating Label Locations
23
Weld, Power, and Engine Specifications
23
Air Compressor Specifications (Air Pak Models)
23
Environmental Specifications
23
Dimensions, Weights, and Operating Angles
24
Duty Cycle and Overheating
24
Volt-Ampere Curves (800 Models)
25
Volt-Ampere Curves (600 Models)
26
AC Generator Power Curves
27
Fuel Consumption
28
Section 5 − Installation
29
Installing Welder/Generator
29
Installing Exhaust Pipe
30
Connecting the Battery
31
Using the Battery Disconnect Switch
31
Engine Prestart Checks
32
Connecting to Weld Output Terminals
33
Making Dual Operator CC Weld Connections W/ Separate Work Cables (800 Models)
34
Making Dual Operator Mode CC Weld Connections W/ Common Work Cable (800 Models)
35
Making Dual Operator CV Weld Connections W/ Separate Work Cables (800 Models)
36
Making Dual Operator CV Weld Connections W/ Common Work Cable (800 Models)
37
Making Dual Operator CC and CV Weld Connections W/ Separate Work Cables (800 Models)
38
Making Dual Operator CC and CV Weld Connections W/ Common Work Cable (800 Models)
39
Making Single Operator CC Weld Connections (800 Models)
40
Selecting Cable Sizes
41
Weld Output Terminals
41
Connecting to the Air Compressor (Air Pak Models)
42
Section 6 − Operating Welder/Generator
43
Front Panel Controls (See Section 6-2)
43
Description of Front Panel Controls (See Section 6-1)
44
Engine Starting Sequence
45
Process/Contactor Switch
46
Service Menu
47
Arc Control Settings
48
Stick Start Procedure − Scratch Start Technique
50
Lift-Arct TIG with Auto-Stopt and Auto-Cratert
50
Voltage/Amperage Control with 14-Pin Remote Accessory
51
Engine Block Heater Operation
52
Updating Software
53
Summary File
54
Associating Arcreach Devices (Arcreach Models Only)
55
Optional Air Dryer Operation (Air Pak Models)
56
Section 7 − Operating Auxiliary Equipment
57
North American Auxiliary Power Receptacles
57
GFCI Receptacle Information, Resetting and Testing
58
Section 8 − Maintenance
59
Maintenance Label
59
Cleaning Unit
60
Routine Maintenance
60
Checking Generator Brushes
61
Battery Replacement
61
Servicing Air Cleaner
62
Battery Maintenance
63
Engine Speed Adjustment
63
Oil Specifications
63
Servicing Fuel and Lubrication Systems
64
Engine/Generator Overload Protection
65
Voltmeter/Ammeter Error Displays
66
Removing Optional Air Dryer for Service
67
Section 9 − Air Compressor Maintenance (Air Pak Models)
68
Air Compressor Maintenance Label
68
Routine Air Compressor Maintenance
69
Servicing Air Cleaner
70
Compressor Overload Protection
71
Servicing Air Compressor
72
Adjusting Compressor Air Pressure
73
Section 10 − Troubleshooting
74
Troubleshooting
74
Section 11 − Parts List
77
Recommended Spare Parts
77
Section 12 − Electrical Diagrams
78
Section 14 − Run-In Procedure
102
Wetstacking
102
Run-In Procedure Using Load Bank or Resistance Grid
103
Section 15 − Air Compressor Tables
104
Flow of Free Air (CFM) through Orifices of Various Diameters
104
Approximate Air Consumption (Cubic Feet) to Operate Pneumatic Equipment at 70-90 P.S.I.G
105
Section 16 − Generator Power Guidelines
106
5
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Miller Big Blue 800 DUO PRO Specifications
General
Brand
Miller
Model
Big Blue 800 DUO PRO
Category
Welding System
Language
English
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