Miller Electric Miller DU-OP manual Processes, Description, File Engine Drive

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Visit our website at

www.MillerWelds.com

OM-494191 862Q

September 2005

Processes

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

TIG (GTAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

Description

Dual-Operator Engine Driven Welding

Generator

Miller DU-OP™

File: Engine Drive

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Contents Description ProcessesFile Engine Drive Visit our website at OM-494191 862Q SeptemberFrom Miller to You Table of Contents − Operating Auxiliary Equipment Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriquePour les moteurs à essence LE Soudage À L’ARC risque de provoquer des interférencesPour les moteurs diesel Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone− Definitions Symbols And DefinitionsWeld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles DescriptionFuel Consumption AC Generator PowerDuty Cycle And Overheating Exceeding duty cycle can damage unit and void warrantyOverheating Reduce Duty Cycle MinutesCC/DC − Dual Mode CC/DC − Single ModeCV/DC Mode Volt-Ampere CurvesInstalling Welding Generator − InstallationConnecting The Battery Activating The Dry Charge Battery If ApplicableDo not overfill battery cells For 30 MinutesEngine Prestart Checks Installing Exhaust PipeStop engine and let cool FuelWeld Output Terminals Safety Information For Connecting To Weld Output TerminalsUnexpected Weld Output can cause injury or fire Welder a Left Side Welder B Right SideDo not exceed machine duty cycle Welder a Left SideConnect electrode holder cables to Elec- trode receptacles Stop engine Do not exceed machine duty cycleVerse position when using CV weld re Place optional Polarity switches in ReWhen switch is in Straight position Switches are set correctly. See SectionConnect wire feeder cables to CV recep- tacles Connect wire feeder cables to Negative − terminalsBe sure Process Selector switches are Place optional Polarity switch in Re Making Single Operator CC Weld Connections OM-494 150 ft 200 ft 250 ft Selecting Weld Cable Sizes350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Put terminalsAfter installing cylinder, wait at Installing Ether Cylinder Optional Ether Starting AidRemote 14 Receptacle Information Socket InformationDual Operator Operation Remote 14 Receptacle ConnectionsEngine Controls − Operating the Welding GeneratorSee -3for weld control descriptions If light goes on, stop engine and check engine beltWeld Controls See Section Do not switch under load Do not switch under load or with out- put onWeld Control Descriptions See Section CV weld output for MIG is only available− Operating Auxiliary Equipment Generator power is not affected by weld outputVolt And 240 Volt Duplex Receptacles At least once a month, run engine atRoutine Maintenance − Maintenance & TroubleshootingMaintenance Label By the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hoseServicing Fuel And Lubrication Systems Weld/Power Adjusting Engine SpeedServicing Optional Ether Starting Aid CylinderChecking And Replacing Alternator Belt To adjust belt tensionMax Tools Needed 11/16 Stop engine To check belt tensionResetting Fan Belt Safety Shutdown Stop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Optional Spark Arrestor MufflerChecking Generator Brushes Thermostats TP3 And TP4 Internal − Not Shown Circuit ProtectionWelding TroubleshootingFactory Authorized Service Agent check main rectifier SR3 Factory Authorized Service Agent check main rectifier SR2Repair or replace wire feeder Formers T5 thru T10, and control board PC1 or PC5Engine Generator PowerOM-494 Circuit Diagram For Welding Generator − Electrical Diagrams210 657-A Wetstacking − RUN-IN ProcedureMent damage may occur 4exceed duty cycle or equip- ment damage may occur Run-In Procedure Using Load BankCheck oil level frequently dur Ing run-in add oil if neededProcedure at less than Run-In Procedure Using Resistance GridBank/grid From flammablesHas this symbol − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer FrameHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Use ground device as stated Electrical codesApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible96−SEE FIG 92 91 103 102 101 100 25−SEE FIG 910 − Parts List4748 57−SEE FIG 78−SEE FIG 76 75 Item Dia Part Description Quantity Mkgs 189 Front Panel Front Panel -1Item Side Control Panels − Welder B Right Side Shown Side Control Panels -1Item Side Control Panels Generator Rectifier Assembly OM-494 Page Your distributor also gives ServiceSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s