Miller Electric Comprehensive Guide to Troubleshooting Help Codes for Miller Welders
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8-11. Voltmeter/Ammeter Help Displays

1

HL.P

2

HL.P

3

HL.P

4

HL.P

5

HL.P

6

HL.P

20

21

22

23

24

25

Use the Voltmeter/Ammeter help displays to diagnose and correct fault conditions.

.When a help code is displayed

normally weld output has stopped but generator power output may be okay.

.To reset help displays, stop unit and then restart. See item 6 below to reset Help 25 dis- play.

1 Help 20 Display

Indicates a failure of meter display module PC2, or the wiring between PC2 and main control module PC1. If this display is shown, have Facto- ry Authorized Service Agent check PC1, PC2, and the wiring between PC1 and PC2.

2 Help 21 Display

Indicates thermistor TH1 on the main rectifier heat sink has failed. If this display is shown, have Facto- ry Authorized Service Agent check TH1, and the wiring between TH1 and PC1.

3 Help 22 Display

Indicates the rectifier heat sink has overheated. If this display is shown, check generator cooling system and/or reduce duty cycle. Keep en- gine access door closed when run- ning to maintain proper cooling air flow past rectifier. Allow unit to cool before restarting. If problem contin- ues, have Factory Authorized Ser- vice Agent check unit.

4 Help 23 Display

Indicates one of the rectifier output SCR’s has failed. If this display is shown, have Factory Authorized Service Agent check the rectifier SCR’s.

5 Help 24 Display

Indicates weld open circuit voltage (OCV) is too high (above 41 volts dc). If this display is shown, have Factory Authorized Service Agent check main control module PC1.

6 Help 25 Display

Indicates a remote device con- nected to Remote Receptacle RC14 may be faulty. Help 25 is also displayed whenever a remote de- vice has been connected to RC14 and then disconnected. Clear fault by stopping and restarting the unit or by turning Process/Contactor switch to another position. If prob- lem continues, have Factory Autho- rized Service Agent check the re- mote device, filter board PC6, and main control module PC1.

803 562 / 217 357-A

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Contents File Engine Drive OM-4433218 314PProcesses DescriptionFrom Miller to You Table of Contents Warranty HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationIndique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LE Soudage peut provoquer un in cendie ou une explosionDES Organes Mobiles peuvent pro voquer des blessures ’EXPLOSION DE LA Batterie peuRisque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresEn ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMFStd − Definitions− 50 h Std Manufacturer’s Rating Label Some symbols are found only on CE products Symbols And DefinitionsDimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Volt-Ampere Curves Stick ModeMIG Mode TIG ModeThis unit is rated for welding at 250 amperes continuously Curve shows typical fuel use under weld or power loadsFuel Consumption Duty Cycle And Overheating150 125 100 AC Generator Power CurveGrounding1 − InstallationInstalling Welding Generator Location/Airflow ClearanceTo Weld Unit In Place Mounting Welding GeneratorSupporting The Unit Mounting SurfacePoint exhaust pipe in desired di Installing Exhaust PipeTools Needed 1/2 Stop engine and let coolClose door after connecting battery Activating The Dry Charge Battery If ApplicableConnecting The Battery Do not overfill battery cellsOil Coolant Recovery TankEngine Prestart Checks FuelStop engine Connecting To Weld Output TerminalsStick and TIG Welding MIG and Fcaw Welding150 ft 200 ft 250 ft Stop engine Before Connecting to Weld Output terminalsSelecting Weld Cable Sizes Socket Information Connecting To Remote 14 Receptacle RC14Welding Symbols Front Panel Controls See Section − Operating Welding GeneratorDescription Of Front Panel Controls See Section Process/Contactor Switch Settings Process/Contactor SwitchLift-Arc t TIG Lift-ArcStart ProcedureLift-Arc Start Method Touch Do not Strike Like a MatchRemote Voltage/Amperage Control At least once a month, run engine at Generator Power Receptacles− Operating Auxiliary Equipment Routine Maintenance − Maintenance & TroubleshootingMaintenance Label To clean air filter Servicing Air CleanerServicing Engine Cooling System Inspecting And Cleaning Optional Spark Arrestor MufflerDo not set engine speed higher Adjusting Engine Speed On Standard ModelsMay affect engine warranty MaximumRpm max 62.6 Hz 1500 rpm 50 Hz Engine Speed AdjustmentWeld/Power Speed Adjustment Engine Speed No LoadTo drain water from fuel system Servicing Fuel And Lubrication SystemsTo change oil and filter To replace primary canister fuel filterOverload Protection Replace Damaged Brushes Checking Generator BrushesHelp 25 Display Voltmeter/Ammeter Help DisplaysHelp 20 Display Welding TroubleshootingEngine Generator PowerCheck for obstructed throttle solenoid Material Thickness Reference Chart Circuit Diagram For Welding Generator − Electrical Diagrams219 228−E Welding Generator − RUN-IN ProcedureWetstacking Cycle or equipment damage may Run-In Procedure Using Load BankFrom flammables Output and do not exceed dutyRun-In Procedure Using Resistance Grid Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codesFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible 101 111 110 −3 109 108 −2 107 102 103 9897 104 106 105 − Parts List4243 80Fig.12−46665 TE1 Dia Part Description Quantity Mkgs Batt Panel, Front w/Components -1Item Panel, Front w/ComponentsFUEL/HM Control Panel Generator -1Item GeneratorRectifier Assembly Wiring Harnesses Support ServiceYour distributor also gives Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact

Big Blue 300 specifications

The Miller Electric Big Blue 300 is a powerful and versatile engine-driven welder that has become a popular choice for professionals in various industries. Designed to excel in both welding and generator applications, the Big Blue 300 provides reliable performance, advanced technology, and exceptional durability, making it suitable for demanding work environments.

One of the standout features of the Big Blue 300 is its impressive output capabilities. With a maximum welding output of 300 amps, this machine can handle a wide range of welding applications, from stick to TIG and MIG processes. The dual voltage output allows for versatility in the field, accommodating both 120V and 240V power requirements, ensuring you can power tools and equipment directly from the welder.

The Big Blue 300 is equipped with Miller's innovative Clean Air Technology, which ensures that the engine operates efficiently and produces fewer emissions. This feature not only meets environmental standards but also enhances the longevity of the machine. The cooling system is engineered to maintain optimal operating temperatures, extending the life of the engine and related components.

For ease of use, the Big Blue 300 features an intuitive control panel with easy-to-read gauges and simple adjustment settings, allowing operators to quickly set welding parameters. The built-in Fuel Gauge and Hour Meter provide real-time information about fuel levels and usage, enabling efficient operation and maintenance planning.

Another notable characteristic of the Big Blue 300 is its rugged construction. Built to withstand harsh job site conditions, the machine features a durable frame and heavy-duty components that can endure the rigors of everyday use. The oversized wheels and solid axle design enhance portability, making it easy to transport across various terrains.

Additionally, the Big Blue 300 is designed for quiet operation, making it suitable for locations where noise levels are a concern. Its low decibel rating ensures that it won’t disturb the work environment, contributing to a more comfortable and productive atmosphere.

Overall, the Miller Electric Big Blue 300 is a robust engine-driven welder that combines power, efficiency, and portability. Whether working on construction sites, maintenance tasks, or fabrication projects, this machine delivers exceptional performance and reliability, making it a valuable tool for professionals who demand the best in their equipment.
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