Miller Electric Miller DU-OP manual California Proposition 65 Warnings, Principal Safety Standards

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READ INSTRUCTIONS.

D Use only genuine MILLER/Hobart replacement parts.

DPerform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als.

H.F. RADIATION can cause interference.

DHigh-frequency (H.F.) can interfere with radio naviga- tion, safety services, computers, and communica- tions equipment.

DHave only qualified persons familiar with electronic equipment perform this installation.

DThe user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

DIf notified by the FCC about interference, stop using the equipment at once.

DHave the installation regularly checked and maintained.

DKeep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

ARC WELDING can cause interference.

DElectromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such as robots.

DBe sure all equipment in the welding area is electro- magnetically compatible.

DTo reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.

DLocate welding operation 100 meters from any sensitive electronic equipment.

DBe sure this welding machine is installed and grounded according to this manual.

DIf interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

1-6. California Proposition 65 Warnings

YWelding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

YBattery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

For Gasoline Engines:

YEngine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

For Diesel Engines:

YDiesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec- tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Bou-

levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or

in Toronto 416-747-4044, website: www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Super- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there are 10 Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power- frequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.

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To reduce magnetic fields in the workplace, use the following procedures:

1.Keep cables close together by twisting or taping them.

2.Arrange cables to one side and away from the operator.

3.Do not coil or drape cables around your body.

4.Keep welding power source and cables as far away from operator as practical.

5.Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:

Pacemaker wearers consult your doctor before welding or going near welding operations. If cleared by your doctor, then following the above procedures is recommended.

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Contents Processes DescriptionFile Engine Drive Visit our website at OM-494191 862Q SeptemberFrom Miller to You Table of Contents − Operating Auxiliary Equipment Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessures’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueLE Soudage À L’ARC risque de provoquer des interférences Pour les moteurs à essencePour les moteurs diesel Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphoneSymbols And Definitions − Definitions− Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles DescriptionAC Generator Power Fuel ConsumptionExceeding duty cycle can damage unit and void warranty Duty Cycle And OverheatingOverheating Reduce Duty Cycle MinutesCC/DC − Single Mode CC/DC − Dual ModeCV/DC Mode Volt-Ampere Curves− Installation Installing Welding GeneratorActivating The Dry Charge Battery If Applicable Connecting The BatteryDo not overfill battery cells For 30 MinutesInstalling Exhaust Pipe Engine Prestart ChecksStop engine and let cool FuelSafety Information For Connecting To Weld Output Terminals Weld Output TerminalsUnexpected Weld Output can cause injury or fire Welder a Left Side Welder B Right SideWelder a Left Side Do not exceed machine duty cycleStop engine Do not exceed machine duty cycle Connect electrode holder cables to Elec- trode receptaclesPlace optional Polarity switches in Re Verse position when using CV weld reWhen switch is in Straight position Switches are set correctly. See SectionConnect wire feeder cables to Negative − terminals Connect wire feeder cables to CV recep- taclesBe sure Process Selector switches are Place optional Polarity switch in Re Making Single Operator CC Weld Connections OM-494 Selecting Weld Cable Sizes 150 ft 200 ft 250 ft350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Put terminalsInstalling Ether Cylinder Optional Ether Starting Aid After installing cylinder, wait atRemote 14 Receptacle Information Socket InformationRemote 14 Receptacle Connections Dual Operator Operation− Operating the Welding Generator Engine ControlsSee -3for weld control descriptions If light goes on, stop engine and check engine beltWeld Controls See Section Do not switch under load or with out- put on Do not switch under loadWeld Control Descriptions See Section CV weld output for MIG is only availableGenerator power is not affected by weld output − Operating Auxiliary EquipmentVolt And 240 Volt Duplex Receptacles At least once a month, run engine at− Maintenance & Troubleshooting Routine MaintenanceMaintenance Label Servicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hoseServicing Fuel And Lubrication Systems Adjusting Engine Speed Weld/PowerServicing Optional Ether Starting Aid CylinderTo adjust belt tension Checking And Replacing Alternator BeltMax Tools Needed 11/16 Stop engine To check belt tensionResetting Fan Belt Safety Shutdown Checking Generator Brushes Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug Circuit Protection Thermostats TP3 And TP4 Internal − Not ShownTroubleshooting WeldingFactory Authorized Service Agent check main rectifier SR2 Factory Authorized Service Agent check main rectifier SR3Repair or replace wire feeder Formers T5 thru T10, and control board PC1 or PC5Generator Power EngineOM-494 − Electrical Diagrams Circuit Diagram For Welding Generator210 657-A Ment damage may occur − RUN-IN ProcedureWetstacking Run-In Procedure Using Load Bank 4exceed duty cycle or equip- ment damage may occurCheck oil level frequently dur Ing run-in add oil if neededRun-In Procedure Using Resistance Grid Procedure at less thanBank/grid From flammables− Generator Power Guidelines Has this symbolSelecting Equipment Grounding Generator To Truck Or Trailer FrameGrounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Use ground device as stated Electrical codesApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 96−SEE FIG 92 91 103 102 101 100 25−SEE FIG 9104748 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 To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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