Miller Electric Miller DU-OP manual Stop engine Do not exceed machine duty cycle

Page 23

5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable

Tools Needed:

3/4 in

YINADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition.

When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative (−) weld termi- nals, and connect a single weld cable of adequate size from the Welder B (right) Negative (−) terminal to the workpiece.

When using these connections as a common work terminal, all connections must be of the same polarity.

For a common work cable connection, the work cable must be able to carry the combined weld output of both modules (see Section 5-15for proper cable size).

Direct Current Electrode Positive (DCEP) connections are shown.

Welder A (Left) Side

Welder B (Right) Side

Note position

of Process

Selector switches.

1

4

2

2

3

Ref. 190 377 / 802 292-A

YStop engine.

YDo not exceed machine duty cycle.

.For common work connection, work

cable must be able to carry combined weld output of both CC weld output ter- minals (see Section 5-15for proper cable size).

.Use Dual Operator mode for CC and CV welding (see Section 6-1).

1 Strain Relief

Route cables through strain reliefs.

2Electrode Holder Cables

3Work Jumper Cable

4 Common Work Cable

For Stick/TIG welding Direct Current Elec- trode Positive (DCEP), connect common work cable and work jumper cable to Weld- er B (right) Negative (−) terminal. Connect other end of work jumper cable to Welder A (left) Negative (−) terminal.

Connect electrode holder cables to CC ter- minals.

For Stick/TIG Direct Current Electrode Negative (DCEN), connect common work cable and work jumper cable to Welder B (right) CC terminal. Connect other end of

work jumper cable to Welder A (left) CC ter- minal.

Connect electrode holder cables to Nega- tive (−) terminals.

If unit has the Polarity switch option, con- nect common work cable and work jumper cable to Welder B (right) Work receptacle. Connect other end of work jumper cable to Welder A (left) Work receptacle.

Connect electrode holder cables to Elec- trode receptacles.

.Be sure Process Selector switches

and optional Polarity switches are set correctly. See Section 6-3.

OM-494 Page 19

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Contents Visit our website at OM-494191 862Q September ProcessesDescription File Engine DriveFrom Miller to You Table of Contents − Operating Auxiliary Equipment Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Surchauffement peut endom- mager le moteur électrique LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures ’EMPLOI Excessif peutBoulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone LE Soudage À L’ARC risque de provoquer des interférencesPour les moteurs à essence Pour les moteurs diesel− Definitions Symbols And DefinitionsDescription − SpecificationsWeld, Power, And Engine Specifications Dimensions, Weights, And Operating AnglesFuel Consumption AC Generator PowerReduce Duty Cycle Minutes Exceeding duty cycle can damage unit and void warrantyDuty Cycle And Overheating OverheatingVolt-Ampere Curves CC/DC − Single ModeCC/DC − Dual Mode CV/DC ModeInstalling Welding Generator − InstallationFor 30 Minutes Activating The Dry Charge Battery If ApplicableConnecting The Battery Do not overfill battery cellsFuel Installing Exhaust PipeEngine Prestart Checks Stop engine and let coolWelder a Left Side Welder B Right Side Safety Information For Connecting To Weld Output TerminalsWeld Output Terminals Unexpected Weld Output can cause injury or fireDo not exceed machine duty cycle Welder a Left SideConnect electrode holder cables to Elec- trode receptacles Stop engine Do not exceed machine duty cycleSwitches are set correctly. See Section Place optional Polarity switches in ReVerse position when using CV weld re When switch is in Straight positionConnect 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 Put terminals Selecting Weld Cable Sizes150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mSocket Information Installing Ether Cylinder Optional Ether Starting AidAfter installing cylinder, wait at Remote 14 Receptacle InformationDual Operator Operation Remote 14 Receptacle ConnectionsIf light goes on, stop engine and check engine belt − Operating the Welding GeneratorEngine Controls See -3for weld control descriptionsWeld Controls See Section CV weld output for MIG is only available Do not switch under load or with out- put onDo not switch under load Weld Control Descriptions See SectionAt least once a month, run engine at Generator power is not affected by weld output− Operating Auxiliary Equipment Volt And 240 Volt Duplex ReceptaclesRoutine Maintenance − Maintenance & TroubleshootingMaintenance Label Do not clean housing with air hose Servicing Air CleanerBy the warranty To clean air filterServicing Fuel And Lubrication Systems Cylinder Adjusting Engine SpeedWeld/Power Servicing Optional Ether Starting AidStop engine To check belt tension To adjust belt tensionChecking And Replacing Alternator Belt Max Tools Needed 11/16Resetting Fan Belt Safety Shutdown Checking Generator Brushes Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug Thermostats TP3 And TP4 Internal − Not Shown Circuit ProtectionWelding TroubleshootingFormers T5 thru T10, and control board PC1 or PC5 Factory Authorized Service Agent check main rectifier SR2Factory Authorized Service Agent check main rectifier SR3 Repair or replace wire feederEngine Generator PowerOM-494 Circuit Diagram For Welding Generator − Electrical Diagrams210 657-A Ment damage may occur − RUN-IN ProcedureWetstacking Ing run-in add oil if needed Run-In Procedure Using Load Bank4exceed duty cycle or equip- ment damage may occur Check oil level frequently durFrom flammables Run-In Procedure Using Resistance GridProcedure at less than Bank/gridGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesHas this symbol Selecting EquipmentUse ground device as stated Electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/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 = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical 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 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