Instruction/ maintenance manual of the product Miller DU-OP Miller Electric
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Miller DU-OP Processes Description Dual-Operator Engine Driven W elding Generator OM-494 191 862Q September 2005 Air Carbon Arc (CAC-A) Cutting and Gouging TIG (GT A W) W elding Stick (SMAW ) W elding MIG (GMAW) W elding Flux Cored (FCA W ) W elding ™ Visit our website at www.
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 7 − OPERA TING AUXILIARY EQUIPMENT 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. 120 V olt And 240 V olt Duplex Receptacles 32 . . . . . . . . . . . . . . . . . . . . . .
OM-494 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05 W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
OM-494 Page 2 W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.
OM-494 Page 3 STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold to avoid scalding. Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).
OM-494 Page 4 READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H. F .
OM-494 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 3/05 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.
OM-494 Page 6 Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées d e l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures.
OM-494 Page 7 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur . Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- ver le bouchon.
OM-494 Page 8 LIRE LES INSTRUCTIONS. Utiliser seulement les pièces de rechange d’origine. Ef fectuer la maintenance du moteur et du compresseur (s i applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RA YONNEMENT HAUTE FRÉ- QUENCE (H.
OM-494 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Stop Engine Start Engine Ether Starting Aid Engine Do Not Switch While W elding Or Under Load Battery (Engine) Circuit Breaker Engi.
OM-494 Page 10 SECTION 4 − SPECIFICA TIONS 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 ).
OM-494 Page 1 1 4-4. Fuel Consumption The curve shows typical fuel use u n - der the combined weld loads of both sides (Welder A and Welder B). 195 71 1 0 50 100 150 200 250 300 350 400 450 500 550 600 DC WELD AMPERES A T 40% DUTY CYCLE CV CC 0 0.25 0.
OM-494 Page 12 4-6. Duty Cycle And Overheating Ref. rduty1 5/95 − 194 313-A Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.
OM-494 Page 13 4-7. V olt-Ampere Curves 194 397 / 194 398 / 194 399 The volt-ampere curve shows the minimum, medium, and maximum voltage and amperage output capa- bilities of the welding generator . Curves of all other settings fall be- tween the curves shown.
OM-494 Page 14 SECTION 5 − INST ALLA TION When facing the front panel, the Welder B controls and weld terminals are on the right and the Welder A controls and weld terminals are on the left. NOTE 5-1. Installing Welding Generator install1 1 1/02* − Ref.
OM-494 Page 15 5-2. Activating The Dry Charge Battery (If Applicable) Always wear a face shield, rubber gloves and protective clothing when working on a battery . Remove battery from unit. 4 V ent Caps 5 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 6 W ell Fill each cell with electrolyte to bottom of well (maximum).
OM-494 Page 16 5-4. Installing Exhaust Pipe Stop engine and let cool. 1/2 in T ools Needed: exh_pipe2 4/96 − 154 089-A / 154 61 1 / 190 377 Do not blow exhaust toward air cleaner or air intake. T op View 5-5. Engine Prestart Checks Full 1/2 in (13 mm) Full Ref.
OM-494 Page 17 5-6. Safety Information For Connecting T o Weld Output T erminals UNEXPECTED WELD OUTPUT can cause injury or fire. Both weld outputs can be live (ON) when Welder Selector switch is in W elder A/W elder B position and engine is running.
OM-494 Page 18 5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. Use Dual Operator mode for CC and CV welding (see Section 6-1). See Section 5-15 for proper cable size.
OM-494 Page 19 5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable Ref. 190 377 / 802 292-A Stop engine. Do 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 5-15 for proper cable size).
OM-494 Page 20 5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. Use Dual Operator mode for CC and CV welding (see Section 6-1). See Section 5-15 for proper cable size.
OM-494 Page 21 5-1 1. Making Dual Operator CV W eld Connections w/ Common W ork Cable Ref. 190 377 / 802 292-A Stop engine. Do 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 5-15 for proper cable size).
OM-494 Page 22 5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. Use Dual Operator mode for CC and CV welding (see Section 6-1). See Section 5-15 for proper cable size.
OM-494 Page 23 5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable Ref. 190 377 / 802 292-A Stop engine. Do 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 5-15 for proper cable size).
OM-494 Page 24 5-14. Making Single Operator CC Weld Connections 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. W elder A (left) weld output terminals are disabled in Single Operator mode. Connect only to Welder B (right) termi- nals for Single Operator mode opera- tion.
OM-494 Page 25 Notes.
OM-494 Page 26 5-15. Selecting W eld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals T urn off power before connecting to weld out- put terminals.
OM-494 Page 27 ether1 7/96 − 153 382-A / 190 377 / 802 291-A Stop engine. Improper handling or expo- sure to ether can harm your health. Follow manufactur- er’s safety instructions on cylinder . Do not use Ether Starting Aid while engine is running.
OM-494 Page 28 5-18. Remote 14 Receptacle Connections Single Operator Operation Dual Operator Operation OR OR OR AJ B K I C L NH D M G E F 60 0 AM PS AJ B K I C L NH D M G E F AJ B K I C L NH D M G E F Ref.
OM-494 Page 29 SECTION 6 − OPERA TING THE WELDING GENERA T OR When facing the front panel, the W elder B controls and weld terminals are on the right and the Welder A side controls and weld terminals are on the left. NOTE 6-1. Engine Controls See Section 6-3 for weld control descriptions.
OM-494 Page 30 6-2. W eld Controls (See Section 6-3 ) Ref. 191 848 8 97 5 6 34 2 60 0 AM PS 300 AMPS 300 AMPS 600 AMPS WELDER A Welder B Welder B 1 10.
OM-494 Page 31 6-3. W eld Control Descriptions (See Section 6-2 ) 1 W elder Selector Switch Use switch to select Dual Operator or Single Operator welding mode. Place switch in W elder A/W elder B (dual oper- ator) position for CC and CV output from W e ld- er A (left) and W elder B (right) weld output ter- minals.
OM-494 Page 32 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. 120 V olt And 240 V olt Duplex Receptacles 190 376 Be sure equipment connected to the 240 V receptacles is GFCI-pro- tected. Generator power is not affected by position of W elder Selector switch.
OM-494 Page 33 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Stop engine before maintaining. S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions.
OM-494 Page 34 8-2. Maintenance Label.
OM-494 Page 35 8-3. Servicing Air Cleaner aircleaner1 2/01 − ST -153 929-B / ST-153 585 / Ref. S-0698-B Stop engine. Do not run engine without air cleaner or wit h dirt y elem ent. En - gine damage caused by using a damaged element is not covered by the warranty .
OM-494 Page 36 8-4. Servicing Fuel And Lubrication Systems Ref. 158 633-C / Ref. 190 377 / Ref. S-176 697 Stop engine and let cool. 1 Oil Filter 2 Oil Drain Plug 3 Oil Drain Hose (Optional) 4 Oil .
OM-494 Page 37 8-5. Adjusting Engine Speed Ref. 045 768-B Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer . See table for proper no load speed. If neces- sary , adjust speed as follows: 1 High Speed Stop Screw 2 Lock Nut Loosen nut.
OM-494 Page 38 8-7. Checking And Replacing Alternator Belt 158 632 / Ref. 190 377 Stop engine. T o check belt tension: Remove rear panel. 1 Alternator V -Belt 2 Crank Pulley 3 Alternator Pulley Place straight edge along top of pul- leys. Pull down belt as far as it will go, then measure distance from belt to straight edge.
OM-494 Page 39 8-8. Resetting Fan Belt Safety Shutdown 158 715 / Ref. 158 632 / Ref. 190 377 Stop engine. 1 Cooling Fan V -Belt See engine manual to replace or tighten belt.
OM-494 Page 40 8-9. Inspecting And Cleaning Optional Spark Arrestor Muffler Ref. 800 633-B / Ref. 190 377 Stop engine and let cool. 1 Spark Arrestor Muf fler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run several min- utes to blow out cleanout hole.
OM-494 Page 41 8-1 1. Circuit Protection Ref. 802 300 / Ref. 802 292-A Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Au- thorized Service Agent. 1 Fuse F1 2 Fuse F2 3 Fuse F3 4 Fuse F4 Open front panel.
OM-494 Page 42 8-12. T roubleshooting A. Welding T rouble Remedy No weld output on either side; generator power output okay at ac receptacles. Place Output (Contactor) switches in On (Hot) position, or place switches in Remote position and connect remote contactors to remote receptacles RC8 and RC9 (see Section 6-3).
OM-494 Page 43 T rouble Remedy Low weld output on both sides. Check engine speed, and adjust if necessary (see Section 8-5). Check position of Process Selector switch(s) (see Section 6-3). Increase Amperage/V oltage controls settings. Have Factory Authorized Service Agent check field current regulator board PC4.
OM-494 Page 44 B. Generator Power T rouble Remedy No output at generator power ac recep- tacles. Reset receptacle circuit breakers (see Section 7-1). Press GFCI reset button on 120 volt GFCI receptacles (see Section 7-1). Check fuse F1, and replace if open (see Section 8-1 1).
OM-494 Page 45 Notes.
OM-494 Page 46 SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator.
OM-494 Page 47 210 657-A.
OM-494 Page 48 SECTION 10 − RUN-IN PROCEDURE run_in3 8/01 10-1. W etstacking 2 1 Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur .
OM-494 Page 49 10-2. Run-In Procedure Using Load Bank S-0683 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur .
OM-494 Page 50 10-3. Run-In Procedure Using Resistance Grid S-0684 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur .
OM-494 Page 51 SECTION 1 1 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. NOTE 1 1-1. Selecting Equipment gen_pwr 1 1/02 − Ref.
OM-494 Page 52 1 1-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
OM-494 Page 53 1 1-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Sta rting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 21.
OM-494 Page 54 1 1-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/.
OM-494 Page 55 1 1-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage.
OM-494 Page 56 1 1-10. T ypical Connections T o Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practic- es. Properly install and ground this equipment according to its Owner ’ s Manual and national, state, and local codes.
OM-494 Page 57 1 1-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
OM-494 Page 58 SECTION 12 − P ARTS LIST Hardware is common and not available unless listed. 12 11 10 8 7 96 − SEE FIG 12-2 95 94 92 91 90 93 89 88 87 97 98 99 100 101 4 1 3 2 9 102 103 10 13 5 6 34 86 84 85 83 37 38 36 35 9 9 15 14 16 17 26 18 32 10 31 33 30 28 25 − SEE FIG 12-4 27 19 20 22 23 24 21 Figure 12-1.
OM-494 Page 59 802 317-D 39 40 41 42 43 44 45 46 47 48 49 51 52 53 54 46 55 56 57 − SEE FIG 12-3 58 59 60 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 37 36 78 − SEE FIG 12-4 35 34 79 80 81 82 50 .
OM-494 Page 60 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 1 605 288 FITTING, pipe galv plug sqhd .250NPT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 070 010 BOL T , J stl .
OM-494 Page 61 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 61 189 764 AIR CLEANER, intake 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-494 Page 62 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 201 915 KIT , label (includes safety and informational labels) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 916 KIT , label (includes safety and informational labels) .
OM-494 Page 63 Description Part No. Dia. Mkgs. Item No. Figure 12-2. Front Panel (Figure 12-1 Item 96) Quantity 1 209056 COVER, receptacle w/gasket 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-494 Page 64 Hardware is common and not available unless listed. 802 320-A 25 26 24 23 22 29 27 28 32 31 30 6 12 18 19 20 21 3 4 5 16 17 15 14 13 11 10 9 34 33 2 1 7 8 35 36 Figure 12-3.
OM-494 Page 65 Description Part No. Dia. Mkgs. Item No. Figure 12-3. Side Control Panels (Figure 12-1 Item 57) Quantity 1 +192 330 P ANEL, side output RH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-494 Page 66 Description Part No. Dia. Mkgs. Item No. Figure 12-3. Side Control Panels (Continued) Quantity 24 039 046 TERMINAL, pwr output black (consisting of) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 039 045 TERMINAL BOARD, black 1 .
OM-494 Page 67 Ref. 048 456-E 1 3 4 5 7 6 9 10 11 8 12 13 15 14 Hardware is common and not available unless listed. 2 Figure 12-4. Generator Description Part No. Dia. Mkgs. Item No. Figure 12-4. Generator (Figure 12-1 Item 78) Quantity 1 *151 299 BRUSH, contact elect clrg .
OM-494 Page 68 Description Part No. Dia. Mkgs. Item No. Figure 12-4. Generator (Continued) Quantity 13 195 704 ST A TOR, exciter aux pwr 120/240 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 173 068 ENDBELL, generator (consisting of) 1 .
OM-494 Page 69 Notes.
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Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor .
PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Compan y 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarte rs − U.
An important point after buying a device Miller Electric Miller DU-OP (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric Miller DU-OP yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric Miller DU-OP - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric Miller DU-OP you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric Miller DU-OP will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric Miller DU-OP, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric Miller DU-OP.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric Miller DU-OP. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric Miller DU-OP along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
