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OM-494 191 862P
January 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
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Engine Hazards . . . . . . . .
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TABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 8-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 8-3. Servicing Air Cleaner
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_8/03 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for nece
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WELDING can cause fire or explosion. HOT PARTS can cause severe burns. Allow cooling period before maintaining. Welding on closed containers, such as tanks, drums, or Wear protective gloves and clothing when working on pipes, can cause them to blow up. Sparks can fly off from the a hot engine. welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal Do not touch hot engine parts or just-welded parts objects can cau
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BATTERY ACID can BURN SKIN and EYES. STEAM AND HOT COOLANT can burn. Do not tip battery. If possible, check coolant level when engine is cold to avoid scalding. Replace damaged battery. Always check coolant level at overflow tank, if pres- Flush eyes and skin immediately with water. ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). If the engine is warm, checking is needed, and there is no overflow tank, ENGINE HEAT can cause fire. foll
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READ INSTRUCTIONS. ARC WELDING can cause interference. Use only genuine MILLER/Hobart replacement Electromagnetic energy can interfere with sensitive parts. electronic equipment such as microprocessors, computers, and computer-driven equipment such as Perform engine and air compressor (if applicable) robots. maintenance and service according to this manual and the engine/air compressor (if applicable) manu- Be sure all equipment in the welding area is electro- als. magnetically compatibl
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure Ce groupe de symboles si- présente des risques de danger ! Ceux-ci sont identifiés par gnifie Mise en garde ! des symboles adjacents aux directives. Soyez vigilant ! Il y a des risques de danger reliés Identifie un message de sécurité partic
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Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B LES ACCUMULATIONS DE GAZ ris- pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi- quent de provoquer des blessures ou mité. même la mort. DES PARTICULES VOLANTES peuvent blesser les yeux. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Le soudage, l’écaillement, le passage de la pièce Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adducti
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Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, L’EXPLOSION DE LA BATTERIE peut débrancher le câble négatif ( −) de batterie de la borne. RENDRE AVEUGLE. Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga- nes mobiles. Toujours porter une protection faciale, des gants en Remettre en place les panneaux ou les dipositifs de protection et fermer les caoutchouc et vêtements de protection lors d’une in- portes à la fin des travaux d’entretien et
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LE SURCHAUFFEMENT peut endom- LIRE LES INSTRUCTIONS. mager le moteur électrique. Utiliser seulement les pièces de rechange d’origine. Effectuer la maintenance du moteur et du compres- Arrêter ou déconnecter l’équipement avant de dé- seur (si applicable) suivant ce manuel et le manuel du marrer ou d’arrêter le moteur. moteur/compresseur (si applicable). Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence tr
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SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Stop Engine Start Engine Ether Starting Aid Engine Do Not Switch While Welding Battery (Engine) Circuit Breaker Engine Oil Or Under Load Check Injectors/ Check Valve Protective Earth Fuel Pump Clearance (Ground) Certified/Trained Positive Negative Welding Arc Mechanic Amperes Volts Panel/Local Remote A V Alternating On Temperature Output (Contactor) Current Stick (SMAW) TIG (GTAW) MIG (GMAW) Three Phase Welding Welding Welding 3 Time Hours Sec
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SECTION 4 − SPECIFICATIONS 4-1. Description This unit has two CC/CV modules with separate weld controls for applications where two welding arcs are needed. A Welder Selector switch controls whether one or both sets of weld output terminals are active (see Section 6-2). When the unit is operated in the dual operator mode, each welder has CC and CV weld output available for Stick, TIG, and MIG welding. When in the single operator mode, CC weld output is available to the welder on the Welder B (rig
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4-4. Fuel Consumption The curve shows typical fuel use un- der the combined weld loads of both sides (Welder A and Welder B). 7.57 1.70 2.00 6.62 1.46 1.75 5.67 1.25 1.50 4.73 1.04 1.25 CC 3.78 0.83 1.00 2.84 0.62 0.75 CV 1.98 0.40 0.50 0.95 0.21 0.25 0 0 50 100 150 200 250 300 350 400 450 500 550 600 DC WELD AMPERES AT 40% DUTY CYCLE 195 711 4-5. AC Generator Power The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 150 300 125 250 100 200 75
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4-6. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. Exceeding duty cycle can Dual Operator Mode − 40% Duty Cycle At 275 Amperes From Each Side damage unit and void Single Operator Mode − 40% Duty Cycle At 550 Amperes From Welder B side (Right) warranty. If a weld module overheats, the High Temperature light goes on and the thermostat opens to stop weld output to that module. Wait fifteen minutes for module to cool. Redu
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4-7. Volt-Ampere Curves The volt-ampere curve shows the A. CC/DC − Single Mode minimum, medium, and maximum 100 voltage and amperage output capa- bilities of the welding generator. Curves of all other settings fall be- tween the curves shown. 80 60 MIN MED MAX 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES B. CC/DC − Dual Mode 100 80 MIN MED MAX 60 40 20 0 0 50 100 150 200 250 300 350 400 450 500 DC AMPERES C. CV/DC Mode 100 80 60 40 MAX MED 20 MIN 0 0 100 200 300 400 5
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SECTION 5 − INSTALLATION When facing the front panel, the Welder B controls and weld terminals are on the NOTE right and the Welder A controls and weld terminals are on the left. 5-1. Installing Welding Generator Movement Airflow Clearance Location 18 in Do Not Lift Unit From End (460 mm) 18 in (460 mm) 18 in (460 mm) OR OR 18 in 18 in (460 mm) (460 mm) Grounding Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT 1 and other applicable codes.
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5-2. Activating The Dry Charge Battery Remove battery from unit. 1 Eye Protection − Safety Glasses Or Face Shield 2 Rubber Gloves 5 3 Vent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 Well 4 1 Fill each cell with electrolyte to 3 bottom of well (maximum). Do not overfill battery cells. Wait ten minutes and check electro- lyte level. If necessary, add electro- lyte to raise to proper level. Reins- tall vent caps. 6 Battery Charger Read and follow all instruc- 2 tions supplied w
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5-3. Connecting The Battery Connect ( −) Cable Last. + − 190 377 5-4. Installing Exhaust Pipe Stop engine and let cool. Do not blow exhaust toward air cleaner or air intake. Top View Tools Needed: 1/2 in exh_pipe2 4/96 − 154 089-A / 154 611 / 190 377 OM-494 Page 16
